Time varying control of the operation of spray systems

ABSTRACT

A sprayer system having dynamic pre-sets to control spray nozzles that each individually operates continuously or under a time-modulated or a frequency-modulated electronic signal control to release liquid droplets. Collectively, adjacent or near neighboring nozzles are also controlled by time-sequencing through different modes of operation or physical configurations on each spray nozzle. The spray nozzles are mounted on a variety of implements including agricultural or industrial spray booms.

RELATED APPLICATIONS

This patent application is a continuation of U.S. patent applicationSer. No. 14/844,619 which is a continuation-in-part of U.S. patentapplication Ser. No. 14/506,057, filed Oct. 3, 2014, and entitled,HYBRID FLOW NOZZLE AND CONTROL SYSTEM, which claims priority to U.S.Provisional Patent Application No. 62/015,315 also entitled HYBRID FLOWNOZZLE AND CONTROL SYSTEM. This patent application claims priority toU.S. patent application Ser. No. 14/505,944, filed Oct. 3, 2014, andentitled, BROADBAND SPRAY NOZZLE SYSTEMS AND METHODS. This patentapplication also claims priority to U.S. Provisional Patent ApplicationSer. No. 62/050,530, filed Sep. 15, 2014, and entitled, TIME VARYINGCONTROL OF THE OPERATION OF SPRAY SYSTEMS. The entire disclosures of theapplications referenced above are incorporated by reference.

FIELD OF THE DISCLOSURE

This disclosure relates generally to the control system of liquidspraying systems.

BACKGROUND OF THE DISCLOSURE

Over twenty-five years ago, a method of using a pulse signal to actuatea valve was introduced to control the flow rate and fluid pressure ofliquids through a spray nozzle. Since then, this technique has remainedlargely the same or unused because it results in spotty spray patternsdue to long dead times, which creates problems in an agriculturalsetting (e.g. crops, plants, trees, vegetables, winery), where sprayersare used to apply nutrients, herbicides, insecticides and water. Inmanufacturing settings, sprayers are used to apply coatings of paintcolors and layers of chemicals, and ink on surfaces (e.g. plastic,paper, semiconductors, metals, and so on).

When pulse signals have been used to control the spray of fluids, theejection of fluid from conventional single nozzles has been controlledby a single signal pulse stream. The voltage polarity of the signalpulse may be arbitrarily selected so that when the pulse is at alogic-HIGH value, then liquid is dispersed by the nozzle, and when thepulse is at a low value, no liquid is dispersed. The ON state isarbitrarily chosen to refer to when liquid is propelled or ejected, andthe OFF state to no liquid. The duration of the ON or OFF pulse can bevaried (PWM, pulse width modulated) to generate an average flow rate, tovary the flow rate and to control the droplet size.

In many settings, not just a single but multiple nozzles are usedtogether. Sprayer systems have multiple nozzle bodies or outlets toapply liquids over a large or intricate surface area. Sometimes theactivity of more than one hundred nozzles is coordinated, which makesPWM control complex.

SUMMARY OF THE DISCLOSURE

Embodiments include a sprayer system having dynamic pre-sets to controlnozzle bodies that each individually operates continuously or under atime-modulated or a frequency-modulated electronic signal control torelease the liquid droplets. Example nozzle bodies have parallel fluidoutputs and different types of nozzle tips on the fluid outputs. Bydynamically switching among the outputs with different nozzle tips,adjusting the electronic signal, and overlapping the spray from adjacentnozzles, the individual nozzle bodies cover a larger dynamic range ofperformance and can hold the fluid droplet size more steadily underdifferent travel speeds. Collectively, adjacent or near neighboringnozzle bodies are controlled by time-sequencing through different modesof operation or physical configurations on each nozzle body, which againcovers a wider range of spray operation. The nozzle bodies are mountedon a variety of implements including agricultural or industrial spraybooms. Other operation modes, features and embodiments are disclosed inthe detailed description, accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of one or more implementations are set forth in theaccompanying example drawings, the description and claims below.

FIG. 1 depicts an example structure or boom having multiple examplenozzles.

FIG. 1A depicts an example spray pattern where the nozzles are spacedapart a distance and the spray from adjacent and next nearest adjacentnozzle overlaps.

FIG. 2 depicts a schematic of an example circuit governing multiplenozzles.

FIG. 3 depicts an example nozzle topology.

FIG. 3A depicts an example timing diagram for the operation of thenozzle topology of FIG. 3.

FIG. 4 depicts an example nozzle topology.

FIG. 4A depicts an example timing diagram for the operation of thenozzle topology of FIG. 4.

FIG. 5 depicts an example nozzle topology.

FIG. 5A depicts an example timing diagram for the operation of thenozzle topology of FIG. 5.

FIG. 6 depicts an example nozzle topology.

FIG. 7 depicts an example nozzle topology.

FIG. 7A depicts an example timing diagram to operate nozzle topology ofFIG. 5.

FIG. 8 depicts an example of a nozzle having a nozzle body with threeoutlets that are covered by nozzle tips.

FIG. 9A depicts another example of a nozzle having a nozzle body withsix outlets that are covered by nozzle tips.

FIG. 9B is an idealized diagram of the fluid flow path inside the nozzlebody of FIG. 9A. The flow path is effectively between an inlet and oneor more of the six outlets.

FIG. 10A depicts example touchscreen for nozzle control.

FIG. 10B depicts example touchscreen for nozzle control with extrafeatures.

FIG. 11A is a flowchart depicting an example overview method to controlthe spray nozzles.

FIG. 11B is a flowchart depicting an example extended method to controlthe spray nozzles.

FIG. 110 is a flowchart depicting an example simplified method tocontrol the spray nozzles.

FIG. 12 is a table listing example control modes of operation for asingle nozzle.

FIG. 13 is a table listing an example method of adjusting the fluidpressure and flow rate.

FIG. 14 is a flowchart in tabular format listing an example method ofsequencing through an example set of spray configurations for fouradjacent nozzles.

FIG. 14A depicts example nozzle fluid release and timing control of thenozzles corresponding to the first block in the method of FIG. 14.

FIG. 14B depicts example nozzle fluid release and timing control of thenozzles corresponding to the second block in the method of FIG. 14.

FIG. 14C depicts example nozzle fluid release and timing control of thenozzles corresponding to the third block in the method of FIG. 14.

FIG. 14D depicts example nozzle fluid release and timing control of thenozzles corresponding to the fourth block in the method of FIG. 14.

FIG. 14E depicts example nozzle fluid release and timing control of thenozzles corresponding to the fifth block in the method of FIG. 14.

FIG. 14F depicts example nozzle fluid release and timing control of thenozzles corresponding to the sixth block in the method of FIG. 14.

FIG. 14G depicts example nozzle fluid release and timing control of thenozzles corresponding to the seventh block in the method of FIG. 14.

FIG. 14H depicts example nozzle fluid release and timing control of thenozzles corresponding to the eighth block in the method of FIG. 14.

FIG. 15 is a flowchart in tabular format listing an example method ofsequencing through another example set of spray configurations for fournozzles.

FIG. 15A depicts example timing control of the nozzles corresponding tothe first block in the method of FIG. 15.

FIG. 15B depicts example timing control of the nozzles corresponding tothe second block in the method of FIG. 15.

FIG. 15C depicts example timing control of the nozzles corresponding tothe tenth block in the method of FIG. 15.

FIG. 16 is a flowchart in tabular format listing an example method ofsequencing through another example set of spray configurations for fournozzles.

FIG. 16A depicts example timing control of one of the nozzles to reset aflow situation where adjacent nozzle bodies are far apart in flow rate.

FIG. 17 is a flowchart in tabular format listing an example method ofsequencing through another example set of spray configurations for fournozzles.

FIG. 17A depicts example timing control of the nozzles corresponding toblock 10 in the method of FIG. 17.

FIG. 17B depicts example timing control of the nozzles corresponding toblock 16 in the method of FIG. 17.

FIG. 17C depicts example timing control of the nozzles corresponding toblock 20 in the method of FIG. 17.

FIG. 18 is a flowchart in tabular format listing an example method ofsequencing through another example set of spray configurations for fournozzles, where an air induction and non-air induction nozzle tips areused on the nozzle outlets.

FIG. 18A depicts example timing control of the nozzles corresponding toblock 5 in the method of FIG. 18.

FIG. 19 depicts an example of two adjacent nozzle bodies that can beextended to four, six, etc.

FIG. 20 depicts an example timing diagram for four or six adjacentnozzles.

FIG. 21 depicts an example timing diagram for four adjacent nozzles.

FIG. 22 depicts an example timing diagram for six adjacent nozzles.

FIG. 23A depicts an example timing diagram for six adjacent nozzles.

FIG. 23B depicts an example spray output for six adjacent nozzles.

FIG. 24A depicts an example timing diagram for six adjacent nozzles.

FIG. 24B depicts example spray pattern related to the method thatproduced the timing diagram of FIG. 24A.

FIG. 25A depicts example spray pattern related to the method thatproduced the timing diagram of FIG. 25B.

FIG. 25B depicts an example timing diagram for six adjacent nozzles.

FIG. 26 depicts an example spray output pattern for six adjacentnozzles.

FIG. 27 depicts an example spray output pattern for six adjacentnozzles.

FIG. 28 depicts an example timing sequence of spray output for fouradjacent nozzles.

FIG. 29 depicts example spray pattern for four adjacent nozzles based ona method that produced the timing sequence of FIG. 28.

FIG. 30 depicts an example nozzles mounted on a sprayer boom.

DETAILED DESCRIPTION

Disclosed example dynamic pre-set embodiments permit easy control of thespray system having many nozzles (nozzle body plus nozzle tips) to covera wide range of spray conditions automatically, eject the fluid quickly,but still uniformly, accurately, without requiring an operator tomanually change nozzle configurations or spray tips on the nozzles. Whenconditions change (e.g. the spray surface or terrain changes), thedisclosed spray systems having dynamic pre-sets provide betterincremental flow rate change resolution than traditional techniques. Thepre-sets attempt to maintain certain measured variables within someperformance range. For instance, the fluid spray pressure is kept within+/−5% from nominal by revising the PWM signal, the nozzle tip, the flowrate, etc. Accordingly, skips in the spray pattern are reduced and thereis more uniform coverage of the target being sprayed.

The example embodiments include electronically wired or wirelesslycontrolled sprayer systems with dynamic pre-sets that have the abilityto coordinate the activity of adjacent or nearby nozzles (housing) inthe sprayer system. The dynamic pre-sets also take advantage of featuresof a new type of nozzle (body and tips). Each nozzle has multipleoutlets, multiple inlets (some embodiments), and multiple valves orgates. Even within a single nozzle, more than one pulse width modulated(PWM) signals may be applied or interleaved to control different valvesthat control fluid flow. The ability to switch among the differentfeatures enables a wider dynamic spray range including wider frequencybandwidth, wider range of pressure, or flow rates so that an end-userdoes not need to stop the vehicle and physically adjust the nozzles orthe rest of the spray vehicle. Alternatively, the different features areinvoked by the pre-sets to maintain a variable (e.g. fluid pressure)within a narrow range. Pre-sets are created to sequence throughdifferent operation states and to make decisions that an operator wouldnot be able to do so because she is located remotely from the nozzles orotherwise unable to adjust them. The pre-sets determine, modulate theduration of the signals, adjust the height of the apparatus, and so on,to control of the spray release from individual nozzles.

In various embodiments, the control is automated after an operatorselects a pre-set that makes dynamic decisions that take into accountother factors (e.g. speed of nozzle or vehicle travel, location, windvelocity, nozzle distance relative to the spray target and so on). Theoperator provides voice commands or touch-screen commands entered into amaster electronic computer or programmable electrical circuit thatgoverns the sprayer system (e.g. spray boom) and also the operation of avehicle on which the sprayer system is mounted. In some embodiments,there is sequencing through the physical modes (e.g. different nozzleoutlets, different valves, and signal duration modulation) on eachnozzle body; or alternatively, sequencing through only modes offrequency operation but keeping the physical configuration (e.g. sameoutlet) constant.

The example embodiments provide better resolution in the incrementalchange in flow rate, and maintain nearly constant pressure (to betterthan 95%) to generate more uniform droplet size. Although thisdisclosure focuses on macroscopic sprayers used in an outdoor field,small sprayers and nozzles for industrial manufacturing or evenmicroelectro-mechanical (MEMs) sized sprayers also benefit from thedisclosed ideas. For instance, industrial uses include a relative motionbetween a sprayer and the target object that may be irregular in shapeor have sharp edges, thus may desire rapid changes in the pattern oramount of spray released.

FIG. 1 depicts an example spray boom assembly 500 having many nozzles502 mounted on or clamped to a fluid distribution pipe (e.g. 504) thatattaches to the boom assembly 500 that is in turn mounted on a dollyplatform, or a vehicle, for example, a tractor or self propelled sprayeror a nutrient applicator towed by a motorized vehicle. The fluiddistribution pipe 504 that carries the fluid is mounted externally to atubular boom or within the hollow of a tubular boom or between thetrusses of the boom assembly 500.

FIG. 1A depicts a front profile view the fluid distribution pipe 504 andthe nozzles 502 releasing a fluid. The nozzles 502 are spaced apart adistance D, and the pipe 504 is at a height H from the target 506, suchthat there is spray overlap between nearest adjacent nozzles 502. Thereis also a little spray overlap, 2%-5%, between next nearest adjacentnozzles 502 in the example of FIG. 1A. Adjustment of the distance D andheight H determines the amount of spray overlap.

FIG. 2 depicts an example machine control 600 system of electronics thatuses CAN-bus 660 as an example communication backbone to coordinate theactivity of many types of signal inputs and interruptions that mayoccur. Machine control 600 includes an operator's central computer 602or server situated at locations on a farm site, a cab of a tractor, oran industrial machine. Machine control 600 as well as any number ofinterrupters (e.g. central computer 602, operator's touchscreen 612 orremote starter, spray interface 614, vehicle information 604,GPS/locator 606, weather inputs 608, boom tracking 610) can interruptthe CAN-bus 660 and take control, including a master spray controller620. Usually there is more than one nozzle 100 or 300 in operation sothat the master spray controller 620 is used to coordinate theactivities of the different nozzles 100 (or 300). The master spraycontroller 620 includes a microprocessor plus peripherals or amicrocontroller (e.g. CPU, memory, etc.) mounted to the spray boomsuspension electronics portal (not shown). The master spray controller620 addresses each nozzle 100 and performs the functions of an interfacefor each nozzle 100 to the CAN bus, controls collective activity,including a synchronization or timing architecture 630 of sprayperformance by simultaneously sending a master clock to each nozzle 100,sequences through programmed instructions including pre-sets for themore likely operational scenarios including turn compensation or a sprayboom assembly 500 (reducing spray), and coordinates needs includingpower management. To reduce the amount of wiring, the master clock andother common signals are distributed or fanned out by atrunk-tree-branch method to four or five sections of nozzles 100 or 300(e.g. 650 on the right hand side of FIG. 2). The branches fan out thesignals via CAN-bus to each individual nozzle 100. Alternatively, thesignals are fanned out to a branch, and within a branch the signals arepassed sequentially from one nozzle to another, regenerated by eachnozzle. Another alternative is a completely sequential distribution ofcommon signals including the clock signals to each nozzle 100.

In other example implementations of the sequencing methods, the masterspray controller 620 sets a master clock under a timing architecture 640as depicted in FIG. 2. The signal of the master clock is relayed fromone nozzle, regenerated by each nozzle to avoid voltage droop, and thenrelayed to the next nozzle (see FIG. 2). Each nozzle 100 (or 300)experiences a slight delay in its local clock relative to the clock ofthe previous nozzle 100. This slight delay prevents a simultaneouselectronic glitch when all of the actuators (e.g. solenoids) turn ON orOFF the valves in a nozzle 100. Alternatively, in timing architectures630 or 650, the master clock is sent simultaneously to the branches ofnozzles 100 along independent wire paths and current or voltage glitchesare isolated by circuits including a small transformer accompanying thesolenoid type actuators. In timing architecture 650, the CAN-bus wiringor local wiring are split in a tree structure with the same length wiresso that each nozzle 100 should receive the clock simultaneously.Sequences of instructions (e.g. pre-sets) are automatically or manually(click-by-click to the next set of instructions by a human operator)exercised by the master spray controller 620 that coordinates all of thenozzles 100. Each individual nozzle 100 has a local nozzle controllercircuit that, for example, modulates the pulse width duration of signalsto open and close the valves on each nozzle 100. For example, the localnozzle controller generates independent pulse signals that control eachof the valves, or generates a combination of pulse signals andcontinuous signals. For special circumstances (e.g. cleaning), a singlesignal is generated and simultaneously opens and close two or morevalves or gates in a single nozzle 100.

Examples of physical spray nozzles 100 and 300 are depicted in FIGS. 8and 9A. Physical spray nozzles 100 and 300 have nozzle bodies 170 and370, respectively. In FIGS. 8 and 9A, the nozzle bodies include an inletand outlets that are connected together by physical structures includinga fluid chamber, tubes, valves and a turret, basically everything inFIGS. 8 and 9A except the nozzle tips (e.g. 130A, 130B, 130C) that capthe outlets. The inlets and outlets refer to a surface or a walledstructure that defines or surrounds an aperture or opening. Thisdisclosure first presents the operation and physical configuration of anindividual nozzle body or holder using idealized drawings. FIGS. 3-7show example nozzle topologies 2A-2E for an individual nozzle body thatincludes at least one fluid inlet, valves to control fluid flow, and atleast one fluid outlet. The valves are often located within a nozzlebody or just on the periphery even though the figures depict them asbeing outside. The outlet(s) are also part of a nozzle body, or just onthe periphery; the outlet permits the release of the fluid. Thetopologies are simplified drawings to aid an understanding of the pathof the fluid flow and the operational mechanism. After much testing anddesign revisions, certain physical implementations were found to workwell, as described below.

FIG. 3 depicts an example nozzle topology 2A having a nozzle body 4Awith two gates or valves 30 and 32 on paths 22 and 24, respectively.Nozzle body 4A selectively releases fluid and droplets to outlet 40.Nozzle topology 2A receives a liquid input from inlet 20, at least aportion of which flows to outlet 40 as controlled by opening and closingthe valves 30 and 32. A fluid can travel either or both of the paths 22and 24 as controlled by valves 30 and 32, respectively. Outlet 40attaches to or may physically be covered by at least a turret body,nozzle tip or nozzle cap. Depending on the end-use purpose, nozzle body4A may be of different shapes, including a hose, a pipe, a sphere, asingle nozzle body with holes, or other geometries. FIG. 3 depicts atopology that may constitute an entire nozzle, or it may constitute onlya portion of a single nozzle. The configuration of FIG. 3 is integratedinto, as part of nozzle body 4E (e.g. left side of nozzle of FIG. 5) sothat two valves open and close to transfer fluids from the inlet 20 to asingle outlet 40. Moreover, valves 30 and 32 may be identical in designor different.

FIG. 3A depicts an example operation of nozzle topology 2A. Electricpulse signals 3 and 5 are applied to respective actuators (not shown ormay be part of the valves) that open and close valves 30 and 32,respectively. For example, the actuator is a plunger-type actuatorincluding an in-line solenoid valve. Each valve 30 or 32 is opened andclosed when an electric current flows through a solenoid (wrapped arounda core) that creates an electromagnetic field to propel the core orpoppet to move. The motion of the core or poppet pushes or pulls valve30 or 32 associated with the core or poppet. Alternatively, linear voicecoil actuators (e.g. hysteresis free, electromagnetic push-pullactuators), electrical-voltage powered, hydraulic or piston valves areused. Electrical valves include running electric power lines along thelength of a spray boom to switch open or close the valve 30 or 32. Inthis disclosure, the polarity is arbitrarily chosen so that a HIGH valueof the signal corresponds to valve open or ON, and a low value of thesignal corresponds to valve closed or OFF. In FIG. 1A, during a fullperiod T of operation of nozzle body 4A, pulse signal 3 is ON more than50% of the duration of period T (over 50% duty cycle), while pulsesignal 5 is ON for less than 50% of the duration of period T (less than50% duty cycle). The duty cycle generally refers to a percentage of timewhen fluid is released to a target object as compared to a total time ofoperation. In the example of FIG. 3A, valve 30 is open to let fluid flowfor more than 50% of a period T and valve 32 is open to let fluid flowfor less than 50% of a period T. The aggregate or resulting signal pulsetrain depicted in FIG. 3A has a frequency that is two times higher thanthe frequency of either pulse signal 3 or 5. Fluid droplets are sprayedtwice as fast as that of a nozzle body 4A having only one valveoperating under a pulse-width modulated signal.

In FIG. 3A, the width of the pulse signals 3 and 5 are fixed; to adjustthe flow rate or fluid pressure, the widths are modulated, increased ordecreased, depending on the duration and on the polarity (regardlesswhether open valve corresponds to ON or OFF). Also, for some types ofchemicals or paints, a manufacturer specifies the optimal amount offluid for best coverage. A corresponding fluid flow rate or flow raterange is preselected to achieve the coverage, which often involvesmodulating the pulse widths to keep within the specified range based onthe speed of travel of the nozzle or vehicle to which nozzles aremounted. Further, to create a dithering effect or a more diffusescattering of the droplets, the duration or frequency of each pulsesignal 3 and 5 is varied or modulated rather than be fixed as shown inexample FIG. 3A. The volume of fluid transferred or sprayed dependspartly on the duty cycle or how long the valves 30 and 32 remain open.The example of FIG. 3A depicts an asymmetric operation and more fluid isreleased from valve 30 than from valve 32. In this example, pulsesignals 3 and 5 are non-overlapping, and they are operating out ofphase. If the entire period T is taken to represent 360 degrees, theleading edge of the pulse signals 3 and 5 are in a range of 250-300degrees apart or out of phase. Signals 3 and 5 are generatedindependently; otherwise, they come from the same parent signal. Forinstance, if signal 3 is the parent signal, it is replicated, thenshifted to generate signal 5; or the leading edge of pulse signal 3operates on valve 30, and the trailing edge of signal 3 operates onvalve 32 (signal 3 is replicated by inversion to present the properpolarity to valve 32). In other examples of operation, the pulse signals3 and 5 overlap or are more symmetric for more repetitive release of theliquid droplets due to either valve 30 or 32. In yet other examples, thesignals 3 and 5 are a sinusoid or ramp rather than a pulse in order tohave a more gradual turn on or turn off of the spray droplets or toapply pressure gradually to the valves to open and close them.

In a paint, nutrient, herbicide or pesticide application embodimentwhere there may be different types of fluids being sprayed, theasymmetric operation of the valves permits achieving different desiredratio of fluids sprayed. When asymmetric fluid spraying is desired, oneexample possibility is to create a divider in the inlet 20 of nozzlebody 4A. The divider (not shown) separates different types of fluids sothat they flow into different chambers within nozzle body 4A and thenare propelled out of nozzle body 4A, separately, by the action of therespective valves 30 and 32. In other examples, when both fluids aremixed together or sprayed simultaneously, the pulse signals 3 and 5overlap for at least a part of the duration of period T.

FIG. 4 depicts another example nozzle topology 2B having a singleoutlet. Nozzle topology 2B has a nozzle body 4B with three valves 30, 32and 34 on paths 22, 24 and 26, respectively, paths that are drawn inparallel in this example. Nozzle body 4B selectively releases fluid anddroplets to outlet 40. Nozzle topology 2B receives a liquid input frominlet 20, at least a portion of which flows to outlet 40 as controlledby opening and closing the valves 30, 32 and 34. Outlet 40 attaches toor may be covered by at least a turret body, nozzle tip or nozzle cap.Depending on the end-use purpose, nozzle body 4B includes a hose, apipe, a sphere, past nozzles with a single nozzle body with holes, orother geometries.

FIG. 4A depicts an example operation of nozzle topology 2B thatparticularly shows how the frequency of fluid release is increased.Electric pulse signals 3 and 5 and 7 are applied to respective actuatorsthat open and close valves 30 and 32 and 34, respectively. In FIG. 4A,during a full period T of operation, pulse signals 3, 5 and 7 are eachON less than 50% of the duration of period T (less 50% duty cycle); theyare ON about 10-20% of the period T and allow fluid to flow through eachvalve for less than 10-20% of a period T. The ON phase of the pulsesignals 3, 5 and 7 are equal in amplitude and duration. The examplethree pulse signals 3, 5 and 7 are shifted in phase by 100-120 degreesso that the aggregate or resulting signal pulse train depicted in FIG.4A has a periodic frequency that is three times higher than the periodicfrequency of any of the individual pulse signal 3, 5 or 7. Accordingly,fluid droplets are sprayed three times higher frequency than that of anozzle body 4B having only one valve operating under a pulse signal 3, 5or 7 alone. To create a dithering effect or diffuse scattering of thedroplets, the duration or frequency of one or all of the pulse signals3, 5 and 7 can be varied (or modulated) rather than be fixed width andfixed frequency as shown in example FIG. 4A. Among other factors, thevolume of fluid transferred or sprayed depends on the duty cycle or howlong the valves 30 and 32 and 34 remain open. In the example of FIG. 4A,there is symmetric operation and the amount of fluid from the threevalves is released uniformly. Since pulse signals 3, 5 and 7 arenon-overlapping, the valves are operating out of phase, and if theentire period is taken to represent 360 degrees, the leading edges ofthe pulse signals 3, 5 and 7 are in a range of 115-125 degrees apart orout of phase from the next one (3 from 5, 5 from 7, 7 from 3). In otherexamples, the pulse signals 3, 5 and 7 overlap or are asymmetric formore overlapping or diffuse spraying of the liquid droplets,respectively. In yet other examples, the signals 3, 5 and 7 aresinusoidal or ramped rather than a pulse in order to have a more gradualturn on or turn off of the spray droplets.

In the examples of FIG. 3A or 4A, other possible valve operationsinclude at least some of the signals shown in FIG. 7A. For instance,valves 30 and 32 operate as shown in FIG. 4A, and valve 34 is ONcontinuously or its frequency of motion is lower or higher than eithervalves 30 or 32. Moreover, the signals include other forms of periodicor semi-periodic signals including sine waves rather than pulses tocreate a more gentle turn on or turn off. Such mixture of operation foran individual nozzle body 4B or nozzle topology 2B is described in theaforementioned provisional patent applications when sequencing throughmultiple nozzle bodies 4B. Continuously refers to a state of being (e.g.an applied voltage, a logic state, valve position) that remains for theduration of an intended action.

FIG. 5 depicts an example nozzle topology 2C having two outlets 40 and42, at one end of paths 22 and 24, respectively. Nozzle topology 2C hasa nozzle body 4C with two valves 30 and 32 on paths 22 and 24,respectively, paths that are drawn in parallel in this example. Valve 30corresponds to outlet 40 and valve 32 corresponds to outlet 42. Nozzlebody 4C selectively releases fluid and droplets to either or bothoutlets 40 or 42. Nozzle topology 2C receives a liquid input from inlet20, at least a portion of which flows to either or both outlets 40 and42 as controlled by opening and closing the valves 30 and 32,respectively. Each outlet 40 or 42 attaches to or may be covered by atleast a turret body, nozzle tip or nozzle cap. Depending on the end-usepurpose, nozzle body 4C includes a hose, a pipe, a sphere, aconventional single nozzle body with holes, or other geometries.

FIG. 5A depicts an example operation of nozzle topology 2C. Forinstance, the operations include electric pulse signals 3 and 5 beingapplied to respective actuators that open and close valves 30 and 32,respectively, to propel liquid out of outlets 40 and 42, respectively.Pulse signals 3 and 5 overlap partially within period T. During a fullperiod T of operation of nozzle body 4C, pulse signals 3 and 5 are ON50% of the duration of period T (50% duty cycle). The phases of pulsesignals 3 and 5 overlap each other by about 90 degrees. Fluid istransferred at the same rate from inlet 20 to either outlet 40 and 42,and the fluid droplets are released at the same rate out of outlets 40and 42, although the release from one lags the other. If the same fluidpressure is maintained as for continuous spraying, the overall volume offluid sprayed under the control of both valves 30 and 32 as depicted inFIG. 3A would be about 25% less than from continuous spraying, but thespray pattern is more tunable and adjustable to suit an operator'sneeds.

If the outlets 40 and 42 are pointed towards different spray directions,their associated spray release have the same overlap as operating pulsesignals 3 and 5 during a period T. The outlets 40 and 42 release sprayindependently. During the non-overlapping time durations of signals 3and 5, only one of the outlets 40 or 42 releases droplets. In theexample of FIG. 5A, the leading edge of pulse signals 3 and 5 areshifted by a constant phase within each period T. Alternatively, thewidth of pulse signals 3 and 5 are varied so that they differ in phase,in the duration of the ON mode, or in frequency in order to achievedifferent spray coverage. In another alternative, if the outlets 40 and42 are pointed toward the same spray direction, the aggregated pulsesignal is indicative of the total amount of fluid released to the targetarea. The aggregate or resulting signal pulse train depicted in FIG. 5Ahas a pulse frequency that is the same as the frequency of either pulsesignal 3 or 5, but the resulting signal has a pulse width that is widerthan either pulse signal 3 or 5, alone, so that fluid is releasedeffectively for a longer duration towards the target spray area. In yetother alternatives, one outlet 40 is spraying continuously, while outlet42 is operated under a pulsed mode PWM or under a frequency modulatedcontrol (FM); or both outlets 40 and 42 are spraying continuously. In apaint, nutrient, herbicide or pesticide application embodiment wherethere may be different types of fluids being sprayed, an asymmetricoperation of the valves 30 and 32 permits achieving different desiredratio of fluids released from respective outlets 40 and 42. Whenasymmetric fluid spraying is desired, one example approach is to createa divider in the inlet 20 of nozzle body 4C. The divider (not shown)separates different types of fluids so that they flow into differentchambers within nozzle body 4C and then are propelled out of nozzleoutlets 40 and 42, separately, by the action of the respective valves 30and 32. In other examples, when both fluids are mixed together orsprayed simultaneously, the pulse signals 3 and 5 overlap for at least apart of the duration of period T.

In addition to adjusting the time duration or frequency of operation ofthe valves 30 and 32, the location of the outlets on nozzle body 4Caffects the spray pattern. For example, outlets 40 and 42 are pointed indifferent directions to generate a wider or more diffuse spray pattern;or outlets 40 and 42 are located parallel to one other but offset by asmall distance (e.g. less four inches); and their spray pattern overlapsand covers a more focused target region. Further, to create a ditheringeffect or a more diffuse scattering of the droplets, the time durationor frequency of each pulse signal 3 and 5 can be varied (or modulated)rather than be fixed as shown in example FIG. 5A. Another possibility isto dither the pulse signals 3 or 5 by adding a randomly generated signalto the pulse signals 3 or 5 in the time domain.

FIG. 6 depicts an example nozzle topology 2D having three outlets 40, 42and 44, at one end of paths 22, 24 and 26, respectively. Nozzle topology2D has a nozzle body 4D with three valves 30, 32 and 34 along paths 22,24 and 26, respectively, paths that are drawn in parallel in thisexample. Nozzle body 4D selectively releases fluid and droplets to atleast one of the outlets 40, 42 or 44. Nozzle 2D topology receives aliquid input from inlet 20, at least a portion of which flows to atleast one of outlets 40, 42 or 44 as controlled by opening and closingthe valves 30, 32 or 34, respectively. Each outlet 40, 42 or 44 attachesto or may be covered by at least a turret body, nozzle tip or nozzlecap. Depending on the end-use purpose, nozzle body 4D includes a hose, apipe, a sphere, a conventional single nozzle body with holes, or othergeometries.

The operation of nozzle topology 2D having three independent outlets 40,42, 44 includes at least all of the operational possibilities describedfor nozzle topology 2C having two independent outlets 40 and 42. Thethird outlet 44 is optionally operating continuously or under pulsedmode or a combination of continuous and pulsed mode.

FIG. 7 depicts a mixed-topology of an example nozzle topology 2E havingtwo outlets 40 and 44, at one end of paths 28 and 26, respectively.Nozzle 2E has a nozzle body 4E with three valves 30, 32, and 34 alongpaths 22, 24 and 26, respectively, paths that are drawn in parallel inthis example. In the arrangement of FIG. 7, paths 22 and 24 merge intopath 28 before reaching outlet 40 (“combined” outlet 40). Nozzle body 4Eoptionally has a third outlet 46 (associated with valve 36). Nozzle body4E releases fluid and droplets to at least one of the three outlets 40,44 or 46 depending on which valves are open and on the internalconfiguration of body 4E. Nozzle topology 2E receives a liquid inputfrom inlet 20, at least a portion of which flows to at least one ofoutlets 40 or 44 or 46 as controlled by opening and closing the valves(30 or 32) or 34 or 36, respectively. The parentheses around “30 and 32”are in reference to fluid at the outlet 40 being dependent on the actionof both valves 30 and 32. Each outlet 40 or 44 or 46 attaches to or maybe covered by at least a turret body, nozzle tip or nozzle cap.Depending on the end-use purpose, nozzle body 4E includes a hose, apipe, a sphere, a conventional single nozzle body with holes, or othergeometries.

FIG. 7A depicts an example operation of nozzle topology 2E. The combinedoutlet 40 nozzle body 4E includes electric pulse signals 3 and 5 beingapplied to respective actuators that open and close valves 30 and 32,respectively, to propel liquid out of outlet 40. In this example, outlet44 or 46 or both are releasing fluid continuously or nearly continuouslyaccording to electric pulse signal 7. Such a nozzle body 4E providesfaster pulse mode operation and extra spray coverage, especially ifoutlets 40 and 44 (or 46) are positioned to point in the same spraytarget area. Alternatively, if the spray trajectories of the outlets(e.g. 40) follow one another in the direction of travel of the sprayvehicle, this provides more complete spray coverage in the pathtraveled. In another embodiment, both the combined outlet 40 and theindividual outlets 44 or 46 are all operating in pulse mode, whether inphase or out of phase. The spray coverage varies depending on thepointing direction of the outlets, the type of tip on the outlets orfilters near the nozzle tip or within the nozzle body 4E, or the shapeof the orifices, and so on.

Different scenarios determine whether one or additional nozzle outletstogether are releasing fluid in FIGS. 5-7. For instance, if the pressureand fluid flow are above a pre-set threshold as measured by a pressureor flowmeter, an additional outlet releases fluid and all the outletsare operating at a more tolerant fluid pressure (where pressure is oftendictated by the delivery of a particular amount of chemical specified tosupply sufficient nutrients or herbicide or paint coverage). To changepressure or flow rate, the pulse width of the applied electric signalsis varied so that more or less liquid is released. Alternatively, thefrequency of the pulses is varied. Another scenario where additionalnozzle outlets release fluid involves the use of air induction nozzlestogether with continuous fluid release rather than pulse width modulatedsignals, so that more than one outlet is in operation to accommodatedifferent types of nozzles. Yet other scenarios include whether thevehicle is making a turn or re-spraying an area for missed spray spots,which would involve different nozzles to be utilized depending on thedesired pattern. For instance, on a turn, the fluid release frequency iscorrespondingly reduced if the vehicle slows down. Alternatively, thespray pattern accounts for the turn down ratio between the nozzletraveling the longest distance on the outer radius and the nozzletraveling the smallest distance on the inner radius. To keep uniform thevolume per area covered through this turn, the flow rate out of theoutermost nozzle should be higher than the flow rate out of theinnermost nozzle.

In the configurations of FIGS. 3-7, only one fluid inlet 20 is shown andthe fluid is distributed among the different outlets depending on thevalve positions and inner configuration of the nozzle body. In anotherconfiguration of the topologies, rather than one fluid inlet 20, thereare two or more fluid inlets. For instance, in FIGS. 3-7, inlet 20channels fluid to outlet 40, while another inlet (not shown) channelsfluids to output 44 or 46. Such additional inlets permit, for example,mixing different chemicals, maintaining different or similar fluidpressure, separate control of droplet sizes and so on. In one example,two inlets are positioned offset to each other so that different fluidpipes or conduits feed the two inlets. For example, extra inlets are forspraying different types of plants co-existing in the same field, or forspraying different coatings on a material.

The aforementioned example topologies are implemented in physicalnozzles 100 and 300 including the ones shown in the figures in theprovisional and previous patent applications that are incorporated inhere by reference. One example nozzle 100 is the one depicted in FIG. 8.Nozzle 100 has fluid inlet 106. Fluid travels to the nozzle tube 102that contains valves to release fluid to the turret 110, which in turnreleases fluid to the outlets of the nozzle 100. Turret 110 has at leasttwo outlets 120A and 120B that are individual independent outlets. Theyare parallel and point in the same direction and are spaced apart byabout 2-4 inches. In this instance, the configuration (of outlets 120Aand 120B) of example nozzle 100 corresponds to topology 2C shown in FIG.5.

In FIG. 8, turret 110 actually has multiple types of outputs, individualoutlets 120A, 120B, 120C, 120D, 120E, 120F, and also 122. End-pointnozzle tips (e.g. 130A, 130B, 130C shown in FIG. 30) are attached to orcap the outlets 120A-120F; the opening pattern of such end nozzle tipsdetermines or affects the spray pattern, flow rate and droplet size.Although drawn as having the same size in FIG. 8, in other embodiments,outlets 120A-120F are different sizes in order to provide a differentspray pattern or to source different amounts of spray; alternatively,the outlets have different strainers inside so as to provide differentdroplet sizes if the strainers have an irregular or particular holepattern to serve both as a sieve for debris to avoid plug-ups and as amechanism to shape the droplets. Outlets 120E and 120F joins togetherinto a combined outlet 122. Turret 110 can be rotated to release fluidfrom the combined outlet 122, which is representative of nozzle topology2A. In other geometries, turret 110 combines or separates fluid flowingthrough a large single outlet hole that opens to two passageways. Theindividual outlets 120A-120F are grouped together in pairs or aligned ina row, with each outlet 120A-120F being perpendicular to a center axis124 of the cylindrical turret 110. Alternatively, if nozzle 100 is animplementation of nozzle topology 2D or 2E, there are additionalindividual outlets 120A-120F grouped together. Outlets 120A-120F aregrouped together in alternative patterns other than as side-by-sidepairs, depending on the end-use application and/or on a desired spraypattern (e.g. location of the crops or other targets). However, whenoutlets 120A-120F are grouped in pairs, the nozzle 100 configurationreadily functions as any one or a combination of the nozzle topologies2C, 2A, 2B, or 2E if the fluid passage way or ducts inside the turret110 is correspondingly appropriately configured, as described in U.S.patent application Ser. No. 14/506,057.

Example actuation mechanisms inside nozzle tube 102 include local orremotely controlled solenoid valves that allow either continuous orpulse width modulated (PWM) spray flow. For continuous flow, at leastone of the solenoid valves remains open over time or the PWM pulsecontrolling the valve is ON all the time. For electro-mechanicalmodulated (e.g. PWM) fluid flow, valves (e.g. plugs 162A and 162B inpatent application Ser. No. 14/506,057) are connected to solenoidshaving open and close positions corresponding to the motion of a steelor iron piece that moves when an inductive coil surrounding the piecehas current flowing in one direction or the opposite direction in thecoil. The motion of the steel or iron piece provides a mechanical forceto open and close plugs 162A or 162B. A controller circuit that is localto the nozzle or to the spray line or located remotely (e.g. cab of asprayer or tractor or at a farmhouse) executes algorithms to open andclose the plugs 162A and 162B to operate and eject a particular spraypattern. Alternative actuation mechanisms include hydraulically orpneumatically actuated valves. Other confined and cost effectiveactuation mechanisms have a speed of operation up to 60 Hertz.

Example nozzle 100 has a nozzle tube 102 that receives liquids at inlet106 at the top of nozzle tube 102. Nozzle 100 is mounted on a fluiddistribution pipe (e.g. spray line, 504) that is inserted in the mountring 107 above the inlet 106. The fluid distribution pipe 504 has holesthat mate to an orifice or opening of nozzles 100 (at inlet 106) inorder to release fluids into inlet 106. Some embodiments include asection valve between the fluid distribution pipe 504 and the inlet 106;alternatively, inlet 106 itself includes a valve to prevent or allowfluid flow into nozzle 100. Fluid selectively travels from nozzle tube102 to turret 110 that is connected to an output of nozzle tube 102.

FIG. 9A depicts another physical nozzle 300 having an inlet 306 coupledto nozzle tubes 360A and 360B (collectively “360”). A rotatable shortcylindrical turret 310 is attached to the nozzle tubes 360. Nozzle tube360 contains plunger type solenoid valves or other valve walls on eachend of the tube 360. When the valves open and close, fluid is releasedfrom the inlet to turret 310. There are actuators acting on the valveslocated inside tube 360; example actuators include solenoid valves,electromagnetic spring coil, pneumatic lever, bellows, and so on. Turret310 is directly attached to the nozzle tube 360; alternatively, turret310 is attached to a rotatable plate 312 that is electronicallycontrolled. Turret 310 contains electronic circuits to operate sensors,the turret rotation, or an optional LED 380 located at the bottom ofturret 310. Turret 310 is manually rotated if there is no plate 312 orautomatically rotated if there is plate 312 and a corresponding motor toturn plate 312 (e.g. stepper motor). The selected nozzle outlet(s) 320A,320B, etc., are positioned to receive fluid from the nozzle tube 360 andspray the fluid onto the target 506.

FIG. 9B is an idealized diagram of the fluid flow path inside the nozzle300 of FIG. 9A. The flow path is represented as being between an inletand one or more of the six outlets, 320A, 320B, . . . 322, at positions1, 2, . . . 6, respectively. In the example of FIGS. 9A and 9B, thereare pairs of outlets positioned such that two outlets are opposite eachother; and there happens to be three pairs of outlets. Any of theseoutlets can be designed and setup as a combined outlet including atposition 1, where both channels A and B empty into the outlet atposition 1. The outlets or channels A and B are actually associated withvalves A and B, respectively, in the nozzle tube 102 or 360. There arealso single outlets including at position 4, having only a single inputsource of fluid from channel A. FIG. 9B depicts an example of the nozzle300 being rotated to a position where the fluid flows to two outletssimultaneously, at positions 1 and 4. In nozzle embodiments 100 and 300,the internal valves, ducts and fluid pathways are designed such thatwhen there is fluid released from a combined outlet, then no other fluidis released from the other outlets. This is based on the configurationof the valves and flow paths inside the turret 110 or 310, as shown inU.S. patent application Ser. No. 14/506,057. In other embodiments, theflow paths in turret 110 or 310 also have a T-section or there areadditional apertures in the internal walls of turret 110 or 310 (seee.g. FIGS. 22 and 26 of patent application Ser. No. 14/506,057), thentwo or more outlets may both serve as combined outlets, simultaneously.

Instead of the combination mode (i.e. a single outlet that combinesfluid from both valves or channels A and B), an operator can also select“single” operation mode, where a first outlet releases fluid only fromvalve or channel A and a second outlet releases fluid only from valve orchannel B. In the example nozzle 300 of FIGS. 9A and 9B, the first andsecond outlets at positions 1 and 4, respectively, happen to be locatedopposite from each other on the periphery of turret 310. An operator maychoose to have both valves/channels A and B release fluid, or may chooseto have only one valve/channel A or B release fluid, which is achievedby setting one corresponding PWM signal ON and the other one OFF. Thesedifferent modes of operation are selectable from a display in the cab ofthe vehicle, or at a remote site including a handheld device or at thefarm building. Example displays are depicted in FIGS. 10A and 10B. InFIGS. 10A and 10B, the word “outlet” is associated with a concept ofchannels or valves A and B as depicted in FIG. 9B.

In FIG. 8 or 9A, nozzles 100 or 300 have example local electroniccircuits to control the fluid flow. To communicate with the nozzle 100or 300, electric wires that carry CAN-bus communication signals from acentralized boom or nozzle controller (e.g. in the cab) are connected tothe electronic leads or pins in or on nozzles 100 or 300. In someembodiments, nozzle 100 or 300 also contains sensors to detect flowrate, temperature, evidence of plug detection, or other problems. Whenthe sensors detect an over-threshold condition, the circuits operate tostop or revise the release of fluid by adjusting the pulse width of PWMsignals to the valves.

Some embodiments include an electronically rotatable turret 110 (or 310)that allows an operator to select one of the nozzle outlets. In oneembodiment, there is nozzle selection circuitry that rotates a steppermotor. The motor rotates a disk on which turret 110 is mounted. Based ona remote or local command signal, the disk rotates so that one or moreof the nozzle outlets including 120A, 120B or 122 point to the targetedspray location. If the outlets 120A, etc., are capped by differentnozzle tips, the operator is thus also able to choose a particularnozzle tip by remote operation or operation from the cab.

Operation

In operation, as shown in FIG. 2, computer circuits control theoperation of the system of many nozzles. In one example, the system'smaster spray controller 620 sends a command to each individual nozzle100 or 300 or to a first nozzle 100 or 300 that propagates the signalsit received. Alternatively, each nozzle 100 or 300 has local circuits togenerate signals to operate its actuators and corresponding valve. Thevalves in the nozzle bodies depicted in FIGS. 3-7 are actuatedelectronically or hydraulically or electro-hydraulically. Programinstructions reside in the circuits or microcontrollers local to anozzle 100 or 300 or in central controller including in the cab of aself propelled sprayer. The instructions are not limited to PWM typesignals or to valve control only, but the microcontroller also executesthe instructions to process data from sensors including the speedometerof the vehicle, wind sensors, and pressure transducers in the fluid pipedistribution, and the microcontroller checks look-up tables to verify ifthe spray is operating at a desired flow rate or at a desired pressure.

In one embodiment, the target spray pressure or spray rate is a prioricalculated based on information including a particular speed of vehicletravel, wind compensation, type of chemical (manufacturing specificationas to the dosage per acre) and the information is placed in a look-uptable stored in the computer's memory as depicted in FIG. 2.Alternatively, a programmed equation is used to dynamically determine(calculate) the amount of spray to be released using the computer'slogic processor circuit; or a lookup table is used jointly with lookuptable entries to determine an appropriate amount of spray release. Aremote starter interrupts or an operator commands the central computer602 to proceed, in which case the computer 602 buffers out an electronicsignal to interface circuits that generate signals using CAN-buscompatible protocol to the master spray controller 620. Usually there ismore than one nozzle 100 or 300 in operation so that the master spraycontroller 620 is used to coordinate the activities of the differentnozzles 100 or 300. The master spray controller 620 is mounted to thespray boom suspension electronics portal (not shown). The master spraycontroller 620 addresses each nozzle 100 or 300 and performs thefunctions of an interface for each nozzle 100 or 300 to the CAN bus. Themaster spray controller 620 also controls or coordinates collectiveactivity including synchronization of spray performance by sending amaster clock to each nozzle 100 or 300, providing turn compensation(reducing spray), and coordinating needs including power management.Alternatively, the master spray controller 620 is more decentralized andsends signals to a first nozzle 100 or 300 that in turn sends signals toa next nozzle 100 or 300.

FIG. 10A depicts an example screen page 660 of a touchscreen 612. Anoperator initiates, interfaces or controls the spray process throughinterfaces including the computer touchscreen 612, or a handheld device(e.g. cellphone with an application, a key fob (frequency operatedremote control)). From screen page 660, the operator selects featuresincluding the spray nozzle being ON or OFF and the rate of sprayapplication (e.g. through touch screen or remotely with a key fob).There are different modes of operation including Auto, Outlet A, OutletB, or Combined (auto or manual). Selecting “Outlet A” or “Outlet B”causes fluid release only out of one outlet. Selecting “Outlet A & B”causes fluid release out of both outlets A and B, but the operator alsoselects other parameters to set the frequency and duty cycle.

Selecting “Auto A & B” causes fluid release out of both outlets A and B,with the controller 620 automatically adjusting the spray to be releasedeither through outlet A or through outlet B or through both outlets Aand B. In the Auto mode, the pre-programmed software instructions in thecontroller 620 selects which of the two outlets A or B is to be used orboth as the speed of travel of the vehicle or the fluid pressure ordroplet size varies. In some cases both A and B will be selected. Thismode helps control the nozzle pressure by switching nozzle tips (whenthe outlets A and B are capped by different nozzle tips) as the speedchanges to keep the spray fluid pressure closer to the target pressurechosen in the input section. In Auto mode, the nozzle assembly isoperated or can be selected to operate in PWM (pulsing) mode andcontroller 620 automatically adjusts the PWM pulse width, frequency oramplitude to reach a target value or to maintain some target variableconstant within 5-10% (e.g. pressure). For example, if the nozzle tipson outlets A and B are different, the dynamic range of spray releasewould be expanded to cover three spray ranges: the nozzle 100 or 300releases spray out of outlet A; then when the endpoint range of outlet Ais reached, the nozzle 100 or 300 transfers to release spray out ofoutlet B until the endpoint range of outlet B is reached; then thenozzle 100 or 300 transfers to release spray out of both outlets A andB. In this example, the controller 620 is preprogrammed as to when toswitch among the outlets based on maintaining a particular variable(e.g. pressure) within a certain magnitude for a particular speed oftravel of the spray vehicle. The nozzle tips may be air induction tips(e.g. for continuous spraying) or tips for PWM operation. The operatorcan select either continuous flow or pulsed flow in conjunction with“Auto A and B.” Further, near adjacent nozzles can extend the range evenmore, for example, if four or more nozzle tips are all different, tips Aand B on a first nozzle body, and tips C and D on the adjacent nozzlebody can span the spray effectively to four spray ranges if all fourtips are different and selected so that their spray ranges are staggeredone after another. If two or even more adjacent nozzle bodies are closeenough so that their spray overlaps on the target area, then having evenmore different tip sizes or different spray types can further extend therange of operation as spray vehicle changes speed. For example, as thevehicle speed changes, the pre-set instructions in the controllerswitches among the nozzles or from one particular nozzle's outlets (i.e.tip to tip) to release fluid, while maintaining the fluid pressure orkeeping some other variable constant. Instead of spray pressure, havingmultiple different nozzle tips and nozzle bodies to switch among canalso extend the range of spray patterns, droplet size, spray direction,and so on.

In the example embodiment of FIG. 10A, the operator can also selectwhether to run the nozzles 100 or 300 in PWM (pulsing) mode orcontinuous mode or some combination of the two modes. For PWM mode, theoperator can choose the frequency of operation of the valves, the dutycycle of the pulse width, and whether to spray out of one or multiplenozzle tips from each nozzle 100 or 300. Alternatively, the operator canselect a target spray pressure that causes the computer to compute or tolook up a desired nozzle 100 spray configuration that will achieve theparticular spray pressure.

In FIG. 10A, an operator can select “A/B Combined”—which causes thefluid to be released out of only one outlet, but both channels A and Binside the nozzle tube (102 or 360) operate to release fluid to the oneoutlet (e.g. 320A or 320B or 122), thus “combining” fluid from bothchannels A and B. This scenario is discussed in U.S. patent applicationSer. No. 14/506,057. FIG. 10B depicts an alternative example of thescreen page 670 on touchscreen 612 as depicted in FIG. 10B, there areadditional example menu 680 including for the operation of a physicalembodiment of nozzle topology 2A, where two or more ducts empty into asingle outlet (A/B Combined). On screen page 670 of FIG. 10B, theoperator can select whether to open and close the two nozzle outlets Aand B in phase or out of phase. Additional selections includeNo-skip-pulsing where the two outlets A and B are operated both on PWMand there is a third outlet C that continuously releases fluid. Anotherselection includes one valve being operated on PWM and another oneremaining open continuously to release fluid from an outlet. In someother embodiments, No-skip-pulsing includes a condition where all theoutlets A and B on each nozzle are pulsed in sequential order so thatthere is always fluid released from each nozzle on the boom (e.g. FIG.17, Flowchart 4).

Turning now to the collective operation of many individual nozzles 100(or 300), nozzles 100 are mounted to a fluid distribution pipe 504 thatsources fluids to the many nozzles simultaneously. Depending on anoperator's spray end-use application, some of the goals includemaintaining a constant spray pressure or flow rate during a steady statesituation. Alternatively, the flow rate is adjusted so as to maintain aconstant pressure (e.g. within 10 PSI) when environmental conditionsvary. For instance, when the spray surface or terrain changes and thevehicle/nozzle travels slower or faster. The following embodimentsprovide sequencing methods for varying spray flow rate by selecting aseries of different operation modes (e.g. by performing or processing asequence) for each nozzle 100 in the collection. Multiple outlets (e.g.40, 44, and 46) are used on each nozzle 100 along with using the largerdynamic range and higher resolution PWM control. Alternatively, othermodulation schemes (e.g. frequency modulation, pulse amplitudemodulation) substitute for PWM. For discussion purposes only, it isinstructive to use a particular example including fifty to one hundredfifty nozzles 100 mounted on a spray boom 500 towed or mounted on avehicle in an agricultural setting; the nozzles 100 are, for example,mounted 10 to 15 inches apart so that their spray output overlaps whenthe spray boom 500 is raised sufficiently high (when the spray edge justbegins to overlap). Sequencing and multiple outlets are used inconjunction with the overlapping of adjacent nozzles 100 and pulse widthmodulation (PWM) to control of the spray release from individual nozzle100. Variables include the distance between spray nozzles, the boomheight, and the type of nozzle tips. These and other nozzle aspects areconfigured so that adjacent nozzles 100 spray at different rates, whichprovides finer resolution in the spray modes. The methods also reducespray pattern skips to provide more uniform coverage and prolong thelife of a nozzle 100.

To accommodate the large number of variables and nozzles 100 (or 300),pre-sets are set up during manufacturing of the spray control system orduring integration of the sprayer vehicle with the boom. Alternatively,an operator programs the instructions or selects instructions among thepre-sets. The capabilities of the pre-sets are due in part to thecapabilities of the individual nozzles 100. Some of the capabilities ofeach nozzle 100 are described above: interleaving the operation of thevalves and combined outputs and individual outputs, all of whichincreases the range of operation, eases use and reduces a need to changenozzles (e.g. nozzle heads) manually.

Before selecting a pre-set operation, an operator first selects theindividual nozzle 100 (or 300) parameters and operating conditions (seee.g. FIG. 11A) including by using an interactive touchscreen (e.g. FIGS.10A and 10B). Alternatively, various parameters are included duringmanufacturing default programming, or end-user setup, test orcalibration situations—such information is for example stored in flashmemory, PROMS or EPROMs embedded in the nozzle local circuits; or suchinformation is stored on the central computer 602 or on cloud serversand downloaded before spray operation.

FIG. 11A depicts a flowchart for an exemplary operation 600 of a hybridnozzle system. An initialization sequence begins in procedure 602, whichincludes testing the communication or data collection systems,calibration, sensing external conditions (e.g. wind direction,temperature), and selecting the type of liquid or mixture. Procedure 604includes selecting the nozzles and nozzle tips that should be operated,setting the amount of overlap among adjacent nozzles or neighboringnozzles (e.g. second adjacent nozzle), rotating and positioning thenozzle (e.g. turret 110 or 310) or spray line 504, and testing thenozzles 100 (or 300) response and test spray pattern. Procedure 606includes selecting the spray mode for the nozzles that are operational.The spray mode includes any of the configurations listed in Table I.Procedure 610 includes a continuous spray mode; procedure 612 includesboth a continuous mode of operation for at least one nozzle or nozzletip and a pulse mode for another nozzle or nozzle tip. Procedure 614includes a PWM pulse mode of operation for a nozzle, having either onevalve or two or more valves pulsing in or out of phase to allow higherflow rates or faster pulsing rates, respectively. Algorithms for any ofthe procedures 610, 612 or 614 may be programmed into the sprayercontroller; for example, a state machine can check the status of thesprayer procedures. For agricultural sprayers, the state machine canalso keep track of other issues including monitoring the terrain, soiland environmental conditions, or position and speed of the vehicle.Finally, in FIG. 11A, procedure 616 includes a method to monitor thespray pattern or quality (i.e. droplet size), involving sensors placedon the rear of or trailing behind the spray vehicle. An expected spraypattern or quality can be pre-loaded on the sprayer controller orcomputing devices. When the detected spray pattern does not match ordeviates too much (e.g. by 5 or 6 sigma) from the expected spray patternor quality, the sprayer controller adjusts the spray rate by changingthe duration of the ON spray time (e.g. revise the ON pulse width).Alternatively, the sprayer controller can also stop, raise, lower, tilt,or rotate the spray line based on detected pressure in the spray lineand/or based on a detected spray pattern. By providing pressure anddetected spray feedback to the sprayer controller, the vehicle canproperly respond. Similarly, in an industrial end use, a spray unit canrespond to problems including a clogged nozzle or overspraying.

The flowchart of FIG. 11B shows an example extended method 700 as towhich parameters are set up for each individual spray nozzle 100 (or300) in an array of nozzles. Several parameters are considered,controlled and/or tracked including the spray control mode (pulsed orcontinuous), spray nozzle tip or nozzles 100 in use (size, type, fanpattern, etc.), whether the valve control flow is combined into outletsor going to individual outlets including tracking a specific turretposition, information about the number of control valves operating andthe mode for each valve (i.e. pulsing phase of valves within a nozzle100, pulsing phase of nozzles 100 to the adjacent nozzles 100, specialsequencing of nozzle 100 pulsing orders, the frequency of each valve,the duty cycle of each valve, and if any special cycle arrangements areused including a double pulse per periods). The example method 700 inthe flowchart is also exercised to adjust or monitor the nozzles as theenvironmental or operating conditions change. In block 710, for eachnozzle 100, nozzle outlet control is performed by sensing or receivinginformation on the turret position, receiving the nozzle model number in712 and setting up the nozzle configuration accordingly in 714. Tocoordinate the activity of all the nozzles 100, an ID number is assignedin 720 to each nozzle 100 along a spray boom or a platform. Depending onthe location of each nozzle 100 along the boom in 722, each particularnozzle 100 is turned on in 730 or off in 724 when a particular region issprayed. When a nozzle 100 is turned to ON in 730, its operationparameters are set in 732 and 734. In block 734, the control modeinformation determines the mode of operation of the nozzles 100. Thecontrol mode information is entered interactively or pre-set includingduring the selection of a mode from the table 800 in FIG. 12. Theoperation mode includes pulsed spraying or continuous spraying. Thecontrol mode can also branch to block 760 to process a sequence ofinstructions after receiving inputs including the target pressure rangein 762 and the actual measured pressure in 764. After calculating thedesired pressure range, block 770 attempts to set an average fluid flowrate by considering factors including the target pressure in 762, speedof travel of the vehicle in 780, wind speed, terrain, and amount ofchemicals prescribed by the fertilizer/herbicide manufacturer in 772,and so on. For pulsed operation starting at block 740, additionalparameters include whether to run a nozzle outlet in PWM mode,calculating or looking-up the duty cycle in 742 and pulse frequency in744. In addition, each single nozzle 100 operation is also determined orselected by parameters including the phase shift between pulses to openand close the valves within a single nozzle 100 (block 746). Likewise,the collective operation is also determined or set by conditionsincluding the phase shift between the valve operation mode for adjacentnozzles 100 (block 748). Special sequences for spraying are selected orset by programming inputs on a console in block 752. For example, toincrease the spray frequency, two pulses per valve are interleaved withpulses of other valves during a fundamental period T.

In some embodiments, automation of some of the operational parameters ofa nozzle 100 or 300 is possible through, for example, sensing theposition of the turret (that is rotated into position either manually orautomatically). RFID or other sensing methods are used to sense thenozzle 100 spray tip brand, model number, and other information that areuseful for setup. Pulling data about the spray nozzle tips andconfigurations is also available from a cloud server, wireless transfer,wire transfer, data cards, hand-held devices, or programmed in theequipment itself. User setups could come from “Apps” that are configuredfor a favorite sequence or use modes. In addition there are Help pagesthat pull data for advice on use or agronomic recommendations for use inan agricultural or forestry setting.

Another example of method 700 to configure parameters is depicted in theflowchart of FIG. 11C. This example method 700 is shorter than theprocedure shown in FIG. 11B. The example of FIG. 11C is a pre-programmedsetup that includes changing the duty cycle of a pulse or the pulsefrequency based on the real-time parameters. The parameters may includenozzle travel speed, duty cycle percentage and boom height, but are notlimited to these. These variables are compared to entries in a lookuptable to determine a new frequency or a new pulse width with which tomodulate the signal. Automated information gathering and applying method700 to the electronic configuration (e.g. FIG. 2) allow dynamic pulsespraying to occur, including increased faster operation when it isdesired.

In addition to pre-sets for a collection of nozzles 100 (or 300), someembodiments include pre-sets for individual nozzles 100 listed in theform of a table on a computer touchscreen or handheld device. Forinstance, FIG. 12 depicts a Table 800 providing example modes ofspraying operation and choices of options related to individual nozzles100 (columns 2-7) and to adjacent nozzles 100 (last column, 8). Each“Mode Number” refers to a state of operation. In this example, the“Spray Control Mode” is either PWM or continuous control of the nozzles100. The “Turret Outlet Position” refers to whether the outlets arecombined (e.g. outlet 40 in FIG. 7 where the fluid input to the outlet40 is from two sources of fluid paths 22 and 24) or are a single outlet(e.g. 44 in FIG. 7). The “Number of Control Valves” refers to examplesincluding depicted in FIG. 7, where it is possible to have either onevalve or both valves source fluid to a turret body part of the nozzlebody (e.g. 2E). If two or more valves are in operation, they can beopen/closed either continuously or pulsed. When the valves are pulsed(PWM) controlled, the pulses applied to each valve are either out ofphase, in phase, or overlapping. The columns “Frequency” and “DutyCycle” refer to the frequency and duty cycle, respectively, of thepulses applied to each valve. The word “same” in the entries refers tothe same value being applied to each valve; and the word “multiple”refers to a variety of values being applied to each valve. The lastcolumn describes the behavior of nozzles 100 or 300 that are locatedadjacent to each other on a fluid distribution pipe (e.g. 504).

In different embodiments, a nozzle (e.g. 2A-2E) has two or more valvesoperating together to control the flow from one inlet 20 to an output. Acontroller device is programmed to switch among different selectedcircuit modes including procedure 1) combined outlet —combining the flowfrom two valves 30 and 32 into one outlet 40 directed to one spraynozzle output; procedure 2) individual outlets—each valve 30 or 32corresponds to a dedicated nozzle outlet 40 or 42, respectively; andprocedure 3) combinations of procedures 1 and 2 when three or morevalves exist (e.g. FIG. 7).

In some embodiments, the listed modes in Table 800 are programmed into acomputing device for controlling the nozzles 100 (or 300); for instance,an end-user then selects a mode through a look-up table, a screen GUI,an APP on a wireless device, and so on. Alternatively a mode isautomatically invoked based on sensed conditions (e.g. weather, winddirection, speed and direction of travel). In some embodiments, thelisted modes from Table 800 are also combined with the operation ofselected nozzles. For example, after an end-user selects a mode ofoperation from the Table 800, adjacent nozzles are also operated 180degrees out of phase, which allows two non-adjacent nozzles on eitherside of one of the pair of adjacent nozzles to overlap (e.g. ABABABA . .. , the spray from the A nozzles overlap), thus providing coverage whenthe adjacent nozzle is OFF.

Returning to Table 800, example Modes 1-18 are operated under a PWMspray scheme and Modes 19-20 under a continuous spray scheme, alone, orin combination with a PWM scheme.

Example Mode 1 uses two or more valves (e.g. 30, 32) to create anintermittent pulsed spray through one combined outlet 40. In this mode,adjacent nozzles spray out of phase from each other by some degree ofseparation (e.g. 180 degrees out of phase for two nozzles or 120 degreesfor three nozzles; however it is also possible that the phase separationis not equally spaced apart). In Mode 1, the pulse frequency and theduty cycle (spray on %) are the same for the two or more valves 30 and32. Variations of Mode 1, include operating the valves 30 and 32 atdifferent frequencies and/or at different duty cycles as shown in Table800 for Modes 2 through 4. Yet another variation of Mode 1 includesputting the valve in phase so they at the same time as shown in Mode 5.And yet another variation includes changing frequency and duty cyclewhile keeping the start, end, or some midpoint of the pulse in phasewith each other while operating as shown in Modes 6 through 8.

Example Modes 9 and 10 include spraying using only one of the multiplevalves for pulsing. For instance, this is achieved by spraying through acombined outlet as in Mode 9 or through individual outlets as in Mode10.

Example Modes 11 through 18 are similar to Modes 1 through 8 except thatthe valves are spraying through individual outlets. In an embodimentwith three or more valves, one way to release spray fluid is through acombined outlet and also an individual outlet, at the same time (e.g.valve 1 and 2 allow spraying through a combined outlet while valve 3sprays through an individual outlet). For example, Modes 13 and 17involve exercising both individual outlets, where each outlet 40 and 42is associated with its own fluid release valve 30 and 32, respectively,in a physical configuration including nozzle 2C (FIG. 5). Valves 30 and32 may be pulsed in phase or out of phase, but they are actuated withthe same frequency or pulse width duration. The pulse width isautomatically or manually varied with vehicle frequency, desiredpressure, flow rate, and so on.

In example Modes 19 and 20, the nozzles spray continuously (i.e. notpulsed spray). In Mode 19 this spray is only sprayed through oneindividual outlet using one valve. For instance, the individual outletis a stand-alone outlet or one of the multiple individual outlets. InMode 20, two or more of the multiple outlets are spraying continuouslyvia multiple valves.

In example Modes 21 through 29, there is at least one outlet sprayingcontinuously while at least one outlet is pulsing. This can bebeneficial to provide good coverage from the continuous spray nozzlewhile using the pulsing nozzle as a way of providing additional flow andadjusting the overall flow. Mode 21 includes one outlet with acontinuous spray and one outlet with a pulsed spray. Modes 22 through 29assumes that at least one valve and outlet are used for the continuousspray and pulsed spray modes with at least one of the modes using two ormore valves and outlets. When two or more valves and outlets are used inthe pulsed spray mode, the pulsing phase, pulse frequency, and dutycycles can either be the same or different as shown in Modes 22 through29.

The entries of Table 800 exemplify some of the capabilities ofindividual nozzles 100 (or 300) that can also be applied in a collective(multi-nozzle) operation. Many of the embodiments include nozzles 100with multiple outlets (e.g. 40 and 42 in FIG. 5) capped with differentnozzle 100 spray tips, each tip having the same or different orificesizes and patterns, but yield the same spray quality (i.e. droplet sizebody's or targets). The master spray controller 620 or nozzle 100controller circuit sequences through a set of individual nozzle 100outlets and spray tips, or through combinations of the nozzle 100outlets and spray tips, to combine nozzles 100 that best fit theconditions (including the amount of chemicals that would providesufficient coverage for the speed at which the nozzle/vehicle istravelling). This allows the ability to change the spray rate or patternas the speed of the vehicle changes or as the speed of the nozzle 100changes in a turn (i.e. one end of the boom travels faster than theother end of the boom when the sprayer is turning and thus may desire ahigher flow rate to compensate for the higher speed). For larger sprayareas or where the area has many possible conditions (e.g. terrainvaries much, or the vehicle or platform dolly carrying the nozzles makesmany turns), a larger range of spray options and modes are madeavailable so that an operator can fine-tune the spraying for his fieldor target.

In various embodiments, the duty cycle is varied dynamically accordingto flow or prescription needs and in order to maintain a constantpressure or pressure within a range. Also two outlets on the same nozzlebody can be operated at different frequencies. Adjacent nozzle bodiescan also operate at different frequencies.

FIGS. 13-29 depict examples of dynamic pre-sets that include differentmethods, actions or instructions to change the PWM or continuous signalsthat drive the actuators to control the fluid flow. Depending on howfast the spray vehicle is accelerating or other factors including howmuch the terrain gradient changes on a variable prescription map, thecontroller may step through many pre-programmed instructions to switchthe signals to the actuators in order to maintain a pre-defined variableincluding nozzle fluid pressure. For example, when the spray speedchanges from 5 to 15 mph in three seconds, the controller would sequencethrough perhaps five to eight instructions within the three to tensecond time period in order to keep the sensed or measured fluidpressure within a desired range (e.g. within +/−10%). Once the sprayvehicle is in a steady-state mode or speed, the controller would tend toremain under the same one or two instructions, possibly switching onlyevery few seconds or minutes. Different factors may be a prioriprogrammed to trigger switching to a different instruction, for examplespeed changes, rate changes from a prescription map, or pressure changesdictated by the operator. The pre-defined variables or conditions thatare being maintained within a defined range include fluid pressurewithin a nozzle 100 or 300, fluid pressure at a section valve along thefluid distribution pipe, spray droplet size, spray drift, flow rate, andso on. If the fluid release from a single nozzle tip is unable to keepthe variable constant or within a desired range, the controller may moveto another option including having the fluid released from anothernozzle tip or from two nozzle tips simultaneously, or the PWM pulsewidth is adjusted, and so on.

Further, dynamic pre-sets include automated methods of sequencingthrough various procedures. The pre-sets would transition sequentially,from instruction to instruction or block to block, 1 to 2 to 3 to 4, andso on. In some embodiments, based on dynamic information from sensors(e.g. travel speed, target surface conditions, fluid pressure, height),certain instructions in the pre-sets are eliminated dynamically ascalculated or by comparison with a look-up table. The instructions thatare eliminated are based, for example, on keeping the fluid pressurewithin a fixed range (e.g. within 20 psi) or keeping the flow ratewithin a fixed range. In various embodiments the dynamic pre-sets arepart of block 734 (“Control Mode”) in method 700 of FIG. 11B.Alternatively, the dynamic pre-sets are part of condensed method 700 ofFIG. 11A, where an operator performs the setup procedure by enteringinformation or selecting a pre-set including by using her console screen612 (FIG. 2).

Starting with a simple embodiment, FIG. 13 depicts an example operation806 having three instructions and nozzle topology 2C having twoindependent outputs, each controlled by its own valve. In actualoperation, the three instructions can be readily exercised automaticallyby a computer processor. Alternatively, an end-user can probably alsomanually perform or switch among only a few instructions including threeinstructions when the user detects some need to exercise a change (e.g.when the spray vehicle turns). For illustration purposes, theconfiguration has four nozzles 100 that are spaced 15 inches or 20inches apart and positioned at a height such that the spray outputsoverlaps. In block 1, each of the four adjacent nozzles 100 nozzlesspray out of its 03 tips; in block 2, each of the four nozzles 100 sprayout of its 04 tips; in block 3, each of the four nozzles 100 spray outof both its 03 and 04 tips. Operation 806 of FIG. 13 displays theresulting pressure and flow rates as the flow rate increases througheach block to revise the droplet size. An operator may implementoperation 806 for purposes including turn compensation, where the outerend of the boom travels faster and should receive a higher fluid flowrate than the inner end of the boom. By adjusting the pressure, the flowrate is correspondingly adjusted, but the change in flow rate depends onwhich transitions are selected among the different blocks (e.g. blocks 1to 2 as opposed to blocks 2 to 3). In this particular example andparticular fluid pipe, the transition goes first from block 1 to 2; the03 nozzle 100 in block 1 climbs to 70 psi before switching to block 2.The transition from block 1 to 2 moves from spraying out of the 03 spraytip to the 04 spray tip and represents a 33% increase in flow rate.However, the transition from block 2 to block 3 moving from the 04 tothe (03+04) nozzle 100 is an increase of 75% in flow rate when the 04tip in block 2 increases to 120 psi before switching to block 3. Suchmanual operation with only a few instructions or blocks may be toocoarse for smooth transition in pressure and flow rate (33% versus 75%increase in one jump) and yet still not fully achieve a desired increasein flow rate during a vehicle turn, vehicle speed change, or other majorenvironmental change. The pressure also went above 120 psi in block 2,which may cause the fluid droplet size profile to change. To have moreadvanced procedures with finer resolution during transitions, theconcept of dynamic pre-sets is introduced.

The following are examples of more complex pre-set sequences for sprayoperation, including the situation where the height of the spray boom isadjusted or the distance between nozzles is adjusted so that the spraycones overlap by, for example, 10-20 percent of the total fluid releasedin each cone. Some sequences include blocks that use both multiplenozzle 100 (or 300) outlets along with pulsing nozzles 100 at 50% dutycycle or continuous spraying at 100%. Other blocks use individualoutlets and multiple control valves to source fluid to the outlets innozzle 100. A pre-set can also be performed in conjunction with anymultiple outlet nozzle 100 arrangement.

An example pre-set Flowchart 1 is shown in FIG. 14 involving fouradjacent nozzles 100 (or 400), each being a multi-outlet nozzle havingat least two outlets including depicted in FIG. 3 (or FIG. 5, outlets 40and 44, for example). Each of the four nozzles 100 (or 300) is outfittedwith a 03 (0.3 gallon per minute) nozzle tip at outlet 1 and 04 (0.4gallon per minute) nozzle tip at outlet 2. Flowchart 1 is fordemonstration purposes, and not limited to only four adjacent nozzles ornozzle tip rating. Flowchart 1 includes a method listed in a tabularformat, as are the other methods or pre-sets. Flowchart 1 demonstrates aprogression of increasing flow rates due to a desired flow rate changeat the nozzles 100 to accommodate situations such a change in speed ofthe sprayer vehicle or a boom turning or variable rate application froma prescription map, and so on. The example setup uses the blocks toincrease flow rate, but the values in the setup can also be modified todecrease the flow rate, or continually adjust the rate up or downdepending on the real-time conditions.

FIGS. 14A-14H depict individual blocks listed in Flowchart 1. In FIG.14A, in block 1, the 03 nozzle tips are pulsing at 50% duty cycle,nozzles bodies 1 and 3 being 180 degrees out of phase with nozzle bodies2 and 4, respectively (i.e. nearest adjacent neighbors are 180 degreesout of phase). As shown in the accompanying timing diagram in FIG. 14A,there is one of the overlapping nozzle bodies spraying in the 100 mscycle. For each nozzle body, valve 1 is ON 50% and OFF 50% of the timeand releases fluid to outlet 1 of each nozzle body. The fluid output isbetween 0.15 to 0.18 gallons per minute and the pressure range isbetween 40 to 70 psi.

In FIG. 14B, in block 2 of Flowchart 1, the 04 nozzle tips are pulsingat 50% duty cycle with nozzles bodies 1 and 3 being 180 degrees out ofphase with nozzles bodies 2 and 4, respectively. Like in block 1, thereis one of the overlapping nozzles bodies spraying in the 100 ms cycle.The output is between 0.20 to 0.25 gallons per minute and the pressurerange is 40 to 90 psi.

In FIG. 14C, in block 3 of Flowchart 1, the outlets 1 (03 nozzles tips)are spraying continuously at 100% duty cycle. The timing diagram in FIG.14C shows how all four nozzles bodies spray continuously. The output isbetween 0.30 to 0.35 gallons per minute and the pressure range is 40 to54 psi.

In FIG. 14D in block 4 of Flowchart 1, the 03 and 04 nozzles tips areeach spraying at 50% duty cycle. There are several ways to exercise thepre-set sequence for the nozzles 100 in this configuration. One way isto have the nearest adjacent nozzles bodies pulse in phase nozzle bodies1 (and 3) using valve 1 and nozzle bodies 2 (and 4) using valve 2 (i.e.valves 1 and 2 of adjacent nozzle bodies are in phase). Nozzles bodies 1(and 3) using valve 2 and nozzles bodies 2 (and 4) using valve 1 are outof phase. The timing graph in FIG. 14D shows there is overlappingcoverage. The output is between 0.35 to 0.40 gallons per minute and thepressure range is 40 to 54 psi.

In FIG. 14E, in block 5 of Flowchart 1, the 04 nozzles tips are sprayingcontinuously at 100% duty cycle. Like the timing diagram for block 3,all four nozzles bodies spray continuously. The output is between 0.40to 0.50 gallons per minute and the pressure range is 40 to 62 psi.

In FIG. 14F, block 6 of Flowchart 1, the 03 nozzles tips are sprayingcontinuously at 100% duty cycle while the 04 nozzle tips spray at 50%duty cycle. The timing graph shows the 03 nozzles tips spraycontinuously while the 04 nozzles tips are pulsing out of phase, butstill provide uniform coverage due to the adjacent nozzle bodies spraycone being overlapping. The output is between 0.50 to 0.55 gallons perminute and the pressure range is 40 to 49 psi.

In FIG. 14G block 7 of Flowchart 1, the 04 nozzles tips are sprayingcontinuously at 100% duty cycle while the 03 nozzle tips spray at 50%duty cycle. Similar to the timing diagram in block 6, but reversing theorder or opening the valves, the 04 nozzles tips spray continuouslywhile the 03 nozzle tips are pulsing out of phase, but still provideuniform coverage due to overlapping spray cones. The output is between0.55 to 0.70 gallons per minute and the pressure range is 40 to 65 psi.

In FIG. 14H block 8 of Flowchart 1, all of the 03 and 04 nozzles tipsare spraying continuously at 100% duty cycle. The output is between 0.7to 0.90 gallons per minute and the pressure range is 40 to 65 psi andthe system can go still higher beyond this.

In the example blocks of Flowchart 1, the turn down ratio is six (turndown relates to the range of flow rates over which the nozzles canoperate, or the ratio between the adjustable minimum spray capacity andthe maximum spray capacity). In every block, the pressure is maintainedbetween 40 to 70 psi with the exception of block 2. There arealternative embodiments to block 2. The turn down ratio of six shouldallow a vehicle speed change by a factor of six times, so that a vehiclecould operate in the field from 4 to 25 miles per hour without asignificant change to the droplet size profile. The turn down ratio ofsix is sufficiently close to a turn down ratio of five that is oftenused for a 120 foot boom with a 30 degree turn radius. Among the blocksof Flowchart 1, there are no nozzles bodies all being off. Should thenozzle bodies be physically near enough to create a double overlap ofspray cones beyond the adjacent nozzle body, there is at least a minimumsingle overlap of the spray cones of the nozzle bodies. Throughout, theflow rate applied at any given time was substantially the same (e.g. towithin 95 percent) or transitioning smoothly with small changes inmagnitude to within five percent. “Substantially the same” refers towithin design, manufacturing, test and measurement tolerances or atleast within 95 percent the same.

In a situation where a constant flow rate as a function of time isdesirable, it may not always be achievable due to external forces. Oneexample solution is to use other values for the duty cycle and not only100% or 50% as shown in Flowchart 1. Other duty cycles are used to fillin gaps or at the low ends of the flow range. Block 2 in Flowchart 1presented a situation where the pressure range went past 70 psi and wasinstead 40 to 90 psi, which may cause a different flow rate duringoperation.

There are alternative embodiments that preserve a pressure range of,say, 40 to 70 psi. For example, the physical nozzle body setup can be asingle outlet rather than two or more outlets. Two valves within eachnozzle are pulsed or actuated to combine fluid to flow into a singleoutlet. The PWM signals controlling the two respective valves aremodulated by relative pulse width durations so that they each alsoaccount for the different size of the nozzle tips 03 and 04 (e.g. byextending the duration of the ON state for one of the valves).

FIG. 15 contains Flowchart 2 that depicts another example method ofsequencing through the spray configurations to maintain the fluidpressure between 40 and 70 psi. Block 4 in Flowchart 2 is added betweenblocks 2 and 3 in the previous example (Flowchart 1) to generate anextra block of resolution. There are a number of example ways toimplement block 4. The first is by having 03 nozzle tip spray at 50%duty cycle while the 04 nozzle tip sprays at 25% duty cycle and atdouble the frequency. For demonstration purposes, the 03 tip is set at10 Hz and the 04 tip set at 20 Hz. And the duty cycle has two pulses pernozzle body before alternating to the other nozzle body. The timinggraph in FIG. 15A shows one such configuration where this is done. Oneaspect of two pulses per nozzle body before alternating to another bodyis that it provides a reasonably uniform spray output, which may also beenhanced by the thickness of the spray droplets, or altered by wind,turbulence, and boom height conditions. The output is between 0.25 to0.30 gallons per minute and the pressure range is 40 to 63 psi and 40 to58 psi in Flowchart 2 as compared to a pressure range of 40 to 90 psi inFlowchart 1. Alternatively, finer resolution is performed bydistributing alternate 04 nozzle tip spraying at 25% duty cycle amongnozzles bodies (i.e. rather than two pulses) at a frequency including 10Hz.

In FIG. 15B, block 2 of Flowchart 2 performs pulsing at 25% duty cycleand double the frequency (in this example 20 Hz) using a sequence whereat least one nozzle body is spraying with single overlap among twonearest adjacent nozzles. The sequence shown in the time graph 85 belowis nozzle body 1 & 3 valve 1, nozzle body 2 & 4 valve 2, nozzle body 1 &3 valve 2, and nozzle body 2 & 4 valve 1. The increased frequency(double) is used to provide more uniform coverage between the adjacentnozzle bodies, but can also instead be performed at the base frequencyor some other frequency. The output is between 0.18 to 0.20 gallons perminute and the pressure range is 40 to 58 psi and 40 to 49 psi for thetwo blocks that replace the one block which had a pressure range of 40to 70 psi.

In FIG. 15C, block 10 of Flowchart 2 shows an example of another setupthat still provides coverage throughout the cycle. In this case the 04nozzle tip is spraying continuously while the 03 nozzle tip sprays at75% duty cycle. In the timing graph of FIG. 15C, the flow rate is notthe same through the cycle period, but there is still spray coverage andthe amount of flow rate variation is less than what would occur withonly one valve releasing fluid per outlet for each nozzle body.

FIG. 16 contains Flowchart 3 that depicts another example method of howto set up the 03 and 04 spray tip configuration on each nozzle bodyusing a twelve action sequence. The Flowchart 3 setup includes twonozzle bodies that are farther apart in flow rate than in the previousexamples. For instance, an end-user has 02 and 10 nozzle tips that heplaces on the nozzle bodies, where 02 refers to 0.2 gallon per minuteflow (at 40 psi) and 10 refers to 1.0 gallon per minute flow (at 40psi). In this example, the nozzle body flow rates between the twooutlets have a difference in the nominal flow by a factor of 5 times. Inthis example, one goal is to keep the sum of the pulse duration time onamong the multiple valves on a nozzle body equal to the total period Tof the cycle. The electronic circuit sends independent signals to eachvalve, but resets all the signals at the stroke of the next period T.For instance, in the case of the 02 and 10 nozzles tips on two outlets,the 02 nozzle body (valve 1) is set at 90% at 10 Hz (i.e. 90 ms of the100 ms cycle), and the 10 nozzle body (valve 2) is set at 10% of the 10Hz to make up the remaining 10 ms of the 10 ms cycle. The timing diagramin FIG. 16A depicts how this example looks on an oscilloscope. Nozzlebodies 1 and 3 have valve 1 (02 nozzle tip) that is ON for 90 ms andvalve 2 (10 nozzle body) is ON for 10 ms. The valves on nozzles bodies 2and 4 are out of phase by 180 degrees with respect to the correspondingvalves on nozzle bodies 1 and 3 in the example timing graph in FIG. 16A.

The mode of operation in Flowchart 3 theoretically allows an infinitenumber of instructions so long as the ON time duration among themultiple valves sums to the total period time T. For practical purposes,the modes may be set up in 1% increments, or for the purpose ofsimplifying the discussion, Flowchart 4 in FIG. 17 depicts an examplewhere there is an increment of 5% in going from procedure block 2 toblock 22.

In block 2 of Flowchart 4, when the 02 nozzle tip is set at 100% dutycycle the 10 nozzle tip is 0%, providing a 0.20 gallon per minute flow.In block 3, the 02 nozzle tip changes to 95% and the 10 nozzle tipchanges to 5% yielding 0.24 gallon per minute of flow. In block 4, the02 nozzle tip changes to 90% and the 10 nozzle tip changes to 10%providing 0.28 gallons per minute of flow, and so on.

FIGS. 17A, 17B and 17C are three timing graphs depicting how the flowcontinues to increase. FIG. 17A (block 10) depicts the 02 nozzle tip(valve 1) at 60% duty cycle and the 10 nozzle tip (valve 2) at 40% dutycycle. FIG. 17B (block 16) depicts the 02 nozzle tip (valve 1) at 30%duty cycle and the 10 nozzle tip (valve 2) at 70% duty cycle. FIG. 17C(block 20) depicts the 02 nozzle tip (valve 1) at 10% duty cycle and the10 nozzle tip (valve 2) at 90% duty cycle.

The example spray application of Flowchart 4 includes a small change inthe spray rate as the vehicle travels, whereas the examples ofFlowcharts 1-3 attempt to keep the spray rate the same throughout thewhole cycle. The example of Flowchart 4 includes a turn down ratio often. By selecting spray tips, using both outlets on a nozzle body andadjusting the boom height, a balance between the turn down ratio and animproved spray coverage is achieved. Regardless, these solutions provideat least some spray coverage during vehicle travel. Agronomists,farmers, or industrial end users can optimize which of the methods toselect for the types or size of spray tips that they mount on each spraynozzle 100.

For air induction nozzles tips, the spray tip is generally set up tospray continuously, but may also operate under PWM control depending onthe physical size of the spray tip. For instance, a larger nozzle bodymay tolerate fine droplets sizes. Alternatively, a non-air-induction tipis also set up to spray either continuously or under PWM control (orsome other form of modulated signal control).

FIG. 18 contains example Flowchart 5 method includes a setup with outlet1 having a 02 nozzle tip with or without air induction that hascontinuous flow, while outlet 2 has a non-air induction 10 nozzle tipthat is pulsed under PWM control. In Flowchart 5, each procedure blockhas 100% duty cycle (continuous flow) assigned to outlet 1 (02 nozzletip, nozzle bodies 1 and 3). In the meantime, as the flow is increase ateach block, outlet 2 (10 nozzle tip, nozzle bodies 2 and 4) isincrementally increase at 5% duty cycle. Flowchart 5 depicts how theflow rate is increased from 0.20 to 1.60 gallon per minute which is aturn down ratio of eight. FIG. 18 A depicts a timing graph for block 5of Flowchart 5.

The example system and methods (e.g. pre-sets Flowcharts 1-5) asdescribed above have multiple blocks (each of which have severalinstructions) to achieve spray precision. In some embodiments, thesystem can be setup for only one of the many scenarios described above.Alternatively, the system can have just a hand-full of settings tochoose from. Another alternative, the system is customizable to many orall of the settings described above. And, the system uses automation(including sensors and computer decisions) to determine the settings.

The aforementioned examples have a constant number of procedures orinstructions but in a fast moving vehicle or where the environmentalconditions change rapidly, some of the blocks are eliminatedautomatically based on how rapidly a parameter is changing or howtime-consuming a particular block can be executed, and so on. Forexample, if the pressure or flow rate is changing rapidly, anintermediary procedure can be eliminated from the list of instructions.As another example, if the vehicle is accelerating or the terraingradient changes rapidly or the vehicle is making a turn, some of theintermediate procedures in a long list of instructions would beexcluded. A spray vehicle speeding accelerating from 5 to 15 mph in 3seconds would sequence through 5 to 8 instructions over a period 3seconds, which limits the number of blocks (or instructions) that can beprocessed. Once the sprayer is at a steady-state speed on an evensurface, it would likely continue to operate in one or two of theblocks, switching to a next block only every few seconds or minutes.When a condition changes sufficiently, this triggers the centralcomputers and Spray Controller electronics to move to execute the nextprocedure or instruction. Condition changes include speed changes, ratechanges from a prescription map, or pressure changes dictated by theoperator. For turn compensation some sections of the boom would have adifferent spray flow rate. Nozzles on the inner wing sections spray less(lower flow rate) and the breakaway sections spray more (higher flowrate).

Depending on the complexity of the end-use application of the sprayersystem, the example methods may be for only one of the many scenariosdescribed above depending on whether the spraying is conducted indoors(no wind, smooth gliding on a dolly platform) or outdoors (e.g. on arugged terrain, many turns and in high wind). The system may bepre-programmed with a hand-full of settings to choose from.Alternatively, the system is customizable to many or all of the settingsdescribed above, or the settings are downloaded from a central farm siteor cloud server on an as-desired basis. Or, the system has automation todetermine the most appropriate settings based on the environmentalconditions detected by sensors that are in communications with themaster operations computer.

During manufacturing or subsequent programming, the calibration or setupof nozzle control sequences is configured through interfaces includingthe central console or display screens (e.g. FIG. 10A). To simplifyspray set up for a novice end-user, the control system establishespre-set sequences to choose from as well as recommended pre-sets to usefor a given collection and number of nozzles 100. Alternatively, thecontrol is also user configured in the case where an operator wants todo something very specific, including deleting a particular instructionor block from any of the methods (pre-sets), or by combining methods.

Additional embodiments include selecting different nozzle tips includingwhen the spray cones from adjacent nozzle bodies overlap. One nozzlebody has one type of spray tip and an adjacent nozzle body has anothertype of spray tip so that there are alternating different types ofnozzle bodies. This is a configuration that may simplify manufacturingand mounting of nozzle tips, where an operator would then buy two typesof nozzle bodies. Adjacent nozzle bodies can also have different shapeof nozzle tips and not just a variation on the flow size. For instance,the arrangement of nozzles alternates between fertilizer nozzles andspray nozzles, or between hollow cone tips, solid cone tips, fan spraytips and so on. The varied arrangement permits spraying of differentchemicals or different spray patterns including banding fluids orspraying into particular locations between the rows.

Although the foregoing procedures are described in the context of anindividual nozzle topology 2C depicted in FIG. 5, another implementationis the nozzle topology of FIG. 3 or 7 (where outlet 40 is used togetherwith one or both of the outlets 44 and 46). There is combined fluid flowfrom two or more valves into one outlet 40, which uses two or morevalves between the inlet and the outlet and pulsing the valves open outof phase with each other (i.e. 180 degrees for two valves, 120 degreesfor 3 valves, etc.) in order to produce a higher overall frequency fluidflow at the outlet 40.

Yet another alternative is to use the topology of FIG. 19 depictingadjacent nozzle bodies 1 and 2, etc., that together, have the ability toachieve higher Frequencies and also span a larger range of frequenciesand modulations by switching among different nozzle tips, differentnozzle bodies and other settings. In the example arrangement of FIG. 19,the adjacent nozzles 1 and 2 are pulsed 180 degrees out of phase. Oradjacent nozzles 1, 3, and 5, etc., are pulsed 180 degrees out of phaserelative to nozzles 2, 4, 6, etc. As shown in FIG. 2C the pulsingsequence is valve 1 on nozzle body 1 followed by valve 3 on the adjacentnozzle body 2, followed by valve 2 on nozzle body 1, followed by valve 4on nozzle body 2. Within the nozzle bodies, valve 1 and valve 2 are 180degrees out of phase with each other thus producing the combined effectof a higher frequency at the outlet of each nozzle.

The severity of spray skipping or dead time where no fluid is releasedto the target area (e.g. time gap between pulses), is reduced byexecuting and switching to another instruction in the sequence and usingdifferent parameters. For example, the pulse width is increased. In thetime graph in FIG. 21 shows four nozzle bodies being actuated at 30%duty cycle at 10 Hz, where nozzles 1 and 3 are out of phase by 180degrees with nozzles 2 and 4 and the result is 20 ms gaps. By sequencingthe spray events in a new arrangement, the period of OFF time is reducedto below 10 ms at a time. In this sequence the nozzle body valvecircuits can open/close either one of the valves, along with using oneor more outlets. In this example, by increasing the pulse duration, itis possible to reduce the dead time gap that occurs between pulses wherethe sprayer is travelling and none of the nozzles bodies are ON.Alternatively, the spraying (e.g. double pulsing) is coordinated withthe travel speed so that there is substantially no skipped spraying.

FIG. 22 is a timing diagram for an example method to control three pairsof adjacent nozzle bodies (six altogether) whose output spray overlaps(triple overlap, e.g. FIG. 27). In this figure, nozzle bodies 2, 4, and6 are pulsing at 20 Hz with all three nozzle bodies in time with eachother. Nozzle bodies 1, 3, and 5 are pulsing at 10 Hz in time with eachother and nozzle bodies 1 and 3 are pulsing at 10 Hz and 180 degrees outof phase with nozzle bodies 1 and 5. Nozzle bodies 1, 3, 5 are all outof phase with nozzle bodies 2, 4, and 6. In this arrangement, the timebetween spray events is reduced from 20 ms to 10 ms. The 10 ms spray OFFtime is also attainable by pulsing all of the nozzle bodies at 20 Hz andevery other one 180 degrees out of phase. One advantage of the scenariodepicted in FIG. 22 is that by using a combination of sequencing andtriple overlap, it is possible to achieve the same result and keep halfthe nozzle bodies pulsing only at 10 Hz, which may increase the life ofthe valve components. In one alternative, the signals are periodicallyswapped so that the 10 Hz nozzle bodies would become 20 Hz nozzle bodiesand vice versa, thus keeping an even amount of wear among all of thenozzle bodies on a boom.

Turning now to further example implementations with fluid spray conesincluding to help an operator perform the collective control of thenozzles 100, the pulse frequency of a pulsing nozzle 100 changesautomatically to optimize the spray output according to the real-timesprayer parameters including vehicle speed, flow rate, and duty cyclepercentage.

In some embodiments, FIG. 23A and corresponding FIG. 23B depict a sprayscenario having six example nozzles and spray cone or spray patternoverlaps twice over (e.g. neighboring even numbered nozzle bodies).Nozzles 1, 3, and 5 are out of phase with nozzles 2, 4, and 6,respectively. The polarity of the signals are selected such that nozzles1, 3, 5 are ON for 10 ms, then from 10 to 50 ms, all nozzles are OFF.From 50 ms to 60 ms, nozzles 2, 4, 6 are ON. From 60 ms to 100 ms allthe nozzles are OFF again. At 100 ms, the cycle starts over again. FIGS.24A and 24B depict how this (FIG. 23A, 23B) works at 50% duty cyclewhere there is at least one set of the nozzles ON throughout the cycle.

FIGS. 25A and 25B are the timing diagrams and corresponding spraypattern that addresses another scenario when the PWM duty cycle is from50% to 100%. There is a period of time when the spray may beover-applying as the vehicle travels forward. In this case, the cyclewould start with nozzles 1, 3, and 5 spraying as shown in case A in FIG.25A, followed by nozzles 1, 2, 3, 4, 5, and 6 all spraying as shown incase B in FIG. 25A, followed by nozzles 2, 4, and 6 spraying as shown incase C in FIG. 25A. If all the six nozzles in this configuration havethe same orifice size (i.e. same flow rate), the result is twice theflow when all nozzles are on as shown in case B. The timing diagram ofFIG. 25B illustrates this. The time where case B has all the nozzles on,the rate is doubled. So, although there is substantially constantcoverage, there is a cyclical rate change as a function of time whilethe vehicle is travelling. In this scenario, an operator canalternatively set the spray in either of two other modes: the duty cyclebeing 100% (ON all the time) or the duty cycle being 50% with adjacentnozzles 180 degrees out of phase.

The scenarios of FIGS. 23-25 can be set up to adjust themselves usingautomated pre-sets having pre-programmed variable frequency control ofthe nozzles depending on primary factors including travel speed and PWMduty cycle. Alternatively, it is also possible to vary the pulse widthor frequency depending on secondary factors including boom height, windspeed, nozzle type, nozzle angle, and spray overlap amount.

Turning now to the overlap of spray patterns from adjacent nozzles andnozzles beyond the adjacent ones. The overlap between spray patterns isprimarily a result of the nozzle spray tip angle size (e.g. angle of 80to 140 degrees), the spacing between the nozzles (typical 15 inches to60 inches), and the height of the boom away from the target area. Thereare other factors that are smaller including spray pressure and how thenozzle is designed. Double overlap refers to two adjacent nozzles oneach side completely cover the pattern of the nozzle between them. FIG.26 shows a double spray overlap setting. FIG. 27 depicts a triple sprayoverlap, where a target area is being sprayed by three nozzles.

As an example under a double overlap, not every adjacent nozzle bodydesires to have the same nozzle outlet activated. By activatingdifferent nozzle outlets, an operator can create a new average outputflow rate from the boom and a new average flow rate to the target. Theexample in FIG. 28 (and accompanying FIG. 29) depicts a spray method asto how an operator can increase a three instruction resolution method tosix instructions by using this principle. In the example of FIG. 28, anoperator has increased the resolution of each instruction and alsogreatly improved the pressure range for each instruction. No oneinstruction allows the pressure to be more than 70 psi. By using theoverlapping nozzles principle, providing different flow to an adjacentnozzle, and increasing the number of instructions to six, an operator isable to move through the 3:1 turndown ratio without much change to thepressure, as indicated in the table of FIG. 29.

The following four tables refer to example situations with each nozzlebody on the spray boom while the vehicle (sprayer) speed changes. Oneembodiment involves switching between two outlets under PWM control asthe vehicle speed increases. For example, the spray system starts withone outlet turned ON, usually at one of the lower pulsing frequencies.As the vehicle speed is increased, the nozzle duty cycle is increaseduntil it is saturated at 100%. At this point, a second outlet turns onat a low duty cycle while the first outlet remains at 100% duty cycle.The table below shows an example of how this embodiment is implementedusing the 03 nozzle tip (outlet 1) and 04 nozzle tip (outlet 2).

Vehicle Nozzle Nozzle Speed flow Press Nozzle 0.3 0.4 MPH GPM psi SizeDC DC  3 0.13 44 0.30  42  0  4 0.15 44 0.30  49  0  5. 0.18 44 0.30  56 0  5.5 0.20 44 0.30  63  0  6 0.22 44 0.30  70  0  6.5 0.24 44 0.30  78 0  7 0.26 44 0.30  85  0  7.5 0.29 44 0.30  92  0  8 0.31 44 0.30  99 0  8.5 0.33 44 0.3 + 0.4 100  4  9 0.35 44 0.3 + 0.4 100 10  9.5 0.3744 0.3 + 0.4 100 15 10 0.40 44 0.3 + 0.4 100 20 10.5 0.42 44 0.3 + 0.4100 25 11 0.44 44 0.3 + 0.4 100 31 11.5 0.46 44 0.3 + 0.4 100 36 12 0.4944 0.3 + 0.4 100 41 12.5 0.51 44 0.3 + 0.4 100 47 13 0.53 44 0.3 + 0.4100 52 13.5 0.55 44 0.3 + 0.4 100 57 14 0.57 44 0.3 + 0.4 100 62 14.50.60 44 0.3 + 0.4 100 68 15 0.62 44 0.3 + 0.4 100 73 15.5 0.64 44 0.3 +0.4 100 78 16 0.66 44 0.3 + 0.4 100 84 16.5 0.68 44 0.3 + 0.4 100 89 170.71 44 0.3 + 0.4 100 94

In this example embodiment, two nozzle tips of the same type and sizeare used to achieve comparable spray quality while increasing thedynamic range as shown in the table below.

Vehicle Nozzle Nozzle Speed flow Press Nozzle 0.3 0.3 MPH GPM psi SizeDC DC  3 0.13 44 0.30  42  0  4 0.15 44 0.30  49  0  5. 0.18 44 0.30  56 0  5.5 0.20 44 0.30  63  0  6 0.22 44 0.30  70  0  6.5 0.24 44 0.30  78 0  7 0.26 44 0.30  85  0  7.5 0.29 44 0.30  92  0  8 0.31 44 0.30  99 0  8.5 0.33 44 0.3 + 0.3 100  6  9 0.35 44 0.3 + 0.3 100  13  9.5 0.3744 0.3 + 0.3 100  20 10 0.40 44 0.3 + 0.3 100  27 10.5 0.42 44 0.3 + 0.3100  34 11 0.44 44 0.3 + 0.3 100  41 11.5 0.46 44 0.3 + 0.3 100  48 120.49 44 0.3 + 0.3 100  55 12.5 0.51 44 0.3 + 0.3 100  62 13 0.53 440.3 + 0.3 100  69 13.5 0.55 44 0.3 + 0.3 100  76 14 0.57 44 0.3 + 0.3100  83 14.5 0.60 44 0.3 + 0.3 100  90 15 0.62 44 0.3 + 0.3 100  97 15.50.64 45 0.3 + 0.3 100 100 16 0.66 49 0.3 + 0.3 100 100 16.5 0.68 520.3 + 0.3 100 100 17 0.71 55 0.3 + 0.3 100 100

In the previous example embodiment, the logic of when to switch may beconfigured depending on user need. The previous example showed that whenthe first outlet was saturated at 100% duty cycle due to the vehiclespeed increase, then a second outlet is turned ON at a low duty cyclewhile the first outlet remained at 100%. But in another embodiment, thelogic may also be configured to switch the first outlet OFF and switchthe larger second outlet to ON. After the second outlet's (tip) dutycycle is saturated to 100%, then both outlets are turned ON and bothpulse at the same duty cycle and the frequency may continue to increasetogether, as shown in the table below.

Vehicle Nozzle Nozzle Speed flow Press Nozzle 0.3 0.4 MPH GPM psi SizeDC DC  3 0.13 44 0.30  42  0  4 0.15 44 0.30  49  0  5. 0.18 44 0.30  56 0  5.5 0.20 44 0.30  63  0  6 0.22 44 0.30  70  0  6.5 0.24 44 0.30  78 0  7 0.26 44 0.30  85  0  7.5 0.29 44 0.30  92  0  8 0.31 44 0.30  99 0  8.5 0.33 44 0.40  0  82  9 0.35 44 0.40  0  88  9.5 0.37 44 0.40  0 94 10 0.40 44 0.3 + 0.4  0 100 10.5 0.42 44 0.3 + 0.4  57  57 11 0.4444 0.3 + 0.4  60  60 11.5 0.46 44 0.3 + 0.4  63  63 12 0.49 44 0.3 + 0.4 66  66 12.5 0.51 44 0.3 + 0.4  69  69 13 0.53 44 0.3 + 0.4  72  72 13.50.55 44 0.3 + 0.4  75  75 14 0.57 44 0.3 + 0.4  78  78 14.5 0.60 440.3 + 0.4  81  81 15 0.62 44 0.3 + 0.4  84  84 15.5 0.64 44 0.3 + 0.4 89  89 16 0.66 44 0.3 + 0.4  93  93 16.5 0.68 44 0.3 + 0.4  96  96 170.71 44 0.3 + 0.4 100 100

In yet another embodiment, both outlets on a nozzle body are turned ONafter the first outlet is saturated at 100% duty cycle and both outletscontinue to pulse at the same duty cycle until they both reachsaturation, as shown in the table below.

Vehicle Nozzle Nozzle Speed flow Press Nozzle 0.3 0.4 MPH GPM psi SizeDC DC  3 0.13 44 0.30  42  0  4 0.15 44 0.30  49  0  5. 0.18 44 0.30  56 0  5.5 0.20 44 0.30  63  0  6 0.22 44 0.30  70  0  6.5 0.24 44 0.30  78 0  7 0.26 44 0.30  85  0  7.5 0.29 44 0.30  92  0  8 0.31 44 0.30  99 0  8.5 0.33 44 0.3 + 0.4  44  44  9 0.35 44 0.3 + 0.4  47  47  9.5 0.3744 0.3 + 0.4  50  50 10 0.40 44 0.3 + 0.4  54  54 10.5 0.42 44 0.3 + 0.4 57  57 11 0.44 44 0.3 + 0.4  60  60 11.5 0.46 44 0.3 + 0.4  63  63 120.49 44 0.3 + 0.4  66  66 12.5 0.51 44 0.3 + 0.4  69  69 13 0.53 440.3 + 0.4  72  72 13.5 0.55 44 0.3 + 0.4  75  75 14 0.57 44 0.3 + 0.4 78  78 14.5 0.60 44 0.3 + 0.4  81  81 15 0.62 44 0.3 + 0.4  84  84 15.50.64 44 0.3 + 0.4  89  89 16 0.66 44 0.3 + 0.4  93  93 16.5 0.68 440.3 + 0.4  96  96 17 0.71 44 0.3 + 0.4 100 100

System

FIGS. 1 and 30 depict nozzles 100 or 300 mounted on or clamped to a boomassembly 500 that is in turn mounted on a dolly platform, or a vehicleincluding a tractor or self propelled sprayer. The fluid distributionpipe 504 that carries the fluid are mounted externally to or locatedinternally to the boom assembly 500. Alternatively, the vehicle includesan aircraft for aerial spraying or hand-operated or lever-operatedknapsack sprayers. Tractor type spraying include low-pressure (e.g.20-50 psi) sprayers that apply about 5-50 gallons per acre. Othertractors include tractor-mounted spray machinery (e.g. tank, pump orflow regulator driven by a hydraulic motor or compressor. Boomassemblies 500 are mounted in the front, rear or one-or-both sides ofthe tractor. In alternative embodiments, tractor mounted sprayer unitsare combined with other equipment including planters, cultivators ortillage implements. Nozzles 100 can be mounted to the ends of a row cropdrop that would enable the nozzles 100 to spray lower, nearer to thecrops, especially after the crops have just emerged. By contrast, thereare high-clearance sprayers tall enough to clear the height of tallercrops including corn. Mounted on either the front or the back of avehicle, the spray boom assembly 500 is lowered or raised, depending oncrop height and application conditions. Alternatively, a trailer-mountedsprayer attached to a wheeled liquid tank and towed through the field bya tractor or a truck or other utility vehicle. Tank capacity ranges upto 1000 to 1500 gallons; a spray fluid pump is mounted on a tractor anddriven by a tractor PTO shaft or other hydraulic motor. For industrialapplications, nozzles 100 are mounted to a boom or to individualizedfluid pump holder so that there may be only one nozzle. Nozzle 100 canbe used for boomless broadcast spraying for either agricultural orindustrial spraying, or even for manually operated or handheld spraysystems.

In FIG. 30, the boom assemblies 500 have a “wet” boom or spray line 504to which a plurality of nozzles 100 (or 100) are attached; the sprayline 504 supplies fluids to each of the nozzles 100 that are spacedapart by 5-100 inches distance, depending mostly on the distance betweencrop rows. Depending on the length of the boom and fluid pipes, thenumber of nozzles range from 20 to about 120. In other embodiments,nozzles 100 (or 300) are attached to a “dry” boom, where hose carryfluids to each nozzle. Like the nozzles, the boom assemblies 500 ortheir elements including the spray line are made in a variety of styles(with or without trusses and different folding mechanisms) and comprisematerials including steel, aluminum, alloys, a composite, carbon fiber,flax fiber, rubber, fiberglass, polymers, plastic, combination of thesematerials and so on. Rivets and connectors that hold together the boom502 segments, struts, channels, are often metallic but may also be ofman-made materials. Rivets and connectors or channels made of heaviermaterial including alloys and metals are sometimes added also to act asweights to stabilize boom assemblies 500 made of lighter material. Aftermuch testing it was found that by including two or more closing (openand close movement) valves to direct the fluid flow from one chamber ofa nozzle to another chamber, along with the use of PWM or continuousflow control (e.g. to increase frequency), the example nozzles 100 thenhave enough flexibility of operation so as to be compatible with amultitude of boom designs, and either lightweight or heavier boomdesigns. Examples of booms include a truss structure; a suspensionsegmented tube, which is suspended from a sprayer center frame boommount, like a suspension bridge with cables emanating from the main(primary) post to the deck beams. Tubular booms without sufficientbraces or trusses may flex more so that faster spray release includingfrom nozzle 100 compensate for any increase in vibration from the boom.Alternatively, since nozzle 100 can release spray faster or slower andis tunable (modulation), its performance can be optimized (tuned) to bemore compatible with the motion of the boom. By modulating and havingmultiple options for the outlets, the dynamic performance of nozzle 100covers a wider range of possible performance (e.g. to accommodate awider range of pressure, flow rate, angle and spray area). Forembodiments with lighter weight booms (e.g. aluminum or compositefiber), a sprayer can instead carry more weight in other ways includingthrough more application material or fluids. For example, a larger tankcan be used or a second spray tank is optionally mounted or docked onthe spray vehicle to accommodate more spray material. The additionalamount of fluids/chemicals sustains a faster spray rate or higher flowrate. As another example, light weight booms 502 can be made longer thanheavier booms (e.g. metallic booms) because they weigh less and thevehicle suspension or the center frame mount can still support theweight of the longer booms 502. Longer booms 502 generally need morenozzles 100 to span the extra length of the boom 502. Approximately100-200 nozzles 100 are mounted to the longer light weight booms 502,which entails additional management and coordination than a situationwith fewer nozzles. In addition, the weight savings from lighter boomsmay also be used towards having additional fluid-distribution pipes.

FIG. 30 depicts an example design for fluid distribution pipes 504 thatare rigid enough even when expanded to enable uniform spraying andresponse to a spray controller. In order to adjust the direction ofspray, fluid distribution pipe 504 is rotatable about one of itslongitudinal axis and is mounted on a step rotator or something similarto rotate fluid distribution pipe 504 so that nozzles 100 (or 300) arepointing in different directions relative to the targeted spray objects.Further, the master spray controller can cantilever sections of thefluid distribution pipe 504 in order to adjust for slopes in the terrainor for uneven soil. Fluid distribution pipe 504 may be strapped orriveted to long metallic beams inside boom 500. The nozzles 100 arelocated at intervals along the metallic beam. For a tubular, suspensionboom 500, the fluid distribution pipe 504 is mounted behind the boom.The fluid distribution pipe 504 is attached to the joints of the boom aswell as being strapped to sections of the boom 500; the rigid sectionsof the fluid distribution pipe 504 are attached by bolts and hinges; atthe joint where the boom 500 folds, the fluid distribution pipe 504 is aflexible tube. The nozzles 100 are mounted to the fluid distributionpipe 504 at a location ranging from below the center line of the boom500 to the top of the boom 500. The suspension type booms 500 generallyhave a diameter that is larger than the size of the nozzles (i.e. largerthan the 115-135 mm size of the nozzle) so that the boom 500 shouldtouch the ground before a nozzle 100 would. At the end of the boom 500,where the breakaway section has tapered boom sections and the diameterof the boom becomes comparable to the size of a nozzle 100, the fluiddistribution pipe 504 is mounted above the centerline of the breakawaysection.

Alternatively, the fluid distribution pipe 504 is mounted to the jointsections and below the boom 500. The spray 504 is strapped to the boom500, along sections of the boom 500. To avoid possible damage to thenozzles 100 (or 300) when the boom 500 gets close to the ground,sections of the boom 500 including the breakaway has a prop orprotrusion at right angles from the boom so that the extension wouldtouch the ground before a nozzle 100 would. The prop/protrusion foldswhen the boom folds because there is a tension wire running along theend of the extension that automatically pulls in the protruded piece.Alternatively, the boom 500 is U-shaped in cross section, a shell, whereone side of the boom wall is an open space. The U-shaped boom 500 ishollowed out and exposed. The fluid distribution pipe 504 is mountedinside the U-shaped boom 500 and nozzle 100 is hanging underneath thefluid distribution pipe 504 so that nozzle 100 is located at the openingof the boom 500 (at the open part of the U). The boom joint sectionsoccupy the space between two nozzles so that there are nozzles 100 allalong the entire length of the boom 500. By placing the nozzles 100 inthe hollow of the boom, the nozzles 100 are protected. As anotheralternative, the boom 500 has circular openings along the length of theboom and nozzles 100 are seated in the sockets.

The collective system operation of many nozzles takes advantage offeatures of the new nozzles including interleaving the operation ofvalves 30 and 32 within a nozzle, or interleaving the operation ofdifferent outputs on a single nozzle, or interleaving the operation ofadjacent nozzles. One main advantage is improved spray coverage qualityand reduced skips in the spray pattern. Additional advantages includefiner resolution when changing the spray operation or reduced nozzlewear.

Although this disclosure focuses on macroscopic and large sprayersincluding those used in an outdoor field, smaller sprayers and nozzlesfor industrial manufacturing or even microelectro-mechanical (MEMs)sized sprayers also benefit from these ideas. For instance, industrialuses also include a relative motion between a sprayer and the targetobject that may be irregular in shape or have sharp edges, thus may alsodesire rapid changes in the pattern or amount of spray released.Further, the PWM spray method refers to turning the fluid release ON orOFF based on an amplitude of the square wave pulses that actuate thevalves (e.g. solenoid valves). The frequency and duty cycle forcontrolling the flow are adjustable through software and/orelectro-mechanical methods. Although pulse or square waves signals arediscussed as an example in this disclosure, the pulse signals includessquare waves, sine waves, triangle waves or some other periodic signalsmay be substituted in some end-use applications (e.g. to create smoothtransitions from spray and non-spray periods).

Finally, the orientation and directions stated and illustrated in thisdisclosure should not be taken as limiting. Many of the orientationsstated in this disclosure and claims are with reference to the directionof travel of the equipment. But, the directions, e.g. “behind” aremerely illustrative and do not orient the embodiments absolutely inspace. That is, a structure manufactured on its “side” or “bottom” ismerely an arbitrary orientation in space that has no absolute direction.Also, in actual usage, for example, the nozzles and boom equipment maybe operated or positioned at an angle because the implements may move inmany directions on a hill; and then, “top” is pointing to the “side.”Thus, the stated directions in this application may be arbitrarydesignations.

The description of the present disclosure has been presented forpurposes of illustration and description, but is not intended to beexhaustive or limited to the disclosure in the form disclosed.Explicitly referenced embodiments herein were chosen and described inorder to explain the principles of the disclosure and their practicalapplication. Accordingly, various implementations other than thoseexplicitly described are within the scope of the claims.

What is claimed is:
 1. A spray nozzle system, comprising: a spray nozzlebody (i) configured to mount to a fluid distribution pipe and (ii) thatincludes a fluid inlet, a first valve, a second valve, and a combinedoutlet, wherein the fluid inlet is coupled to the combined outlet viathe first valve and the second valve and wherein a fluid received at thefluid inlet is separated into at least two flow paths via the firstvalve and the second valve before recombining into a single flow path atthe combined outlet; an electronic controller; a first actuator (i)communicatively coupled to the electronic controller, (ii) connected tothe first valve, and (iii) responsive to a first pulse-width-modulated(PWM) signal; and a second actuator (i) communicatively coupled to theelectronic controller, (ii) connected to the second valve, and (iii)responsive to a second PWM signal, wherein the first PWM signal is in apredetermined phase relation to the second PWM signal such that fluid isreleased at a greater frequency from the combined outlet than fromeither the first valve or the second value, separately.
 2. The spraynozzle system of claim 1, wherein: in a first sub-mode, the first PWMsignal and the second PWM signal have the same frequency and arein-phase, and in a second sub-mode, the first PWM signal and the secondPWM signal have the same frequency and are out-of-phase.
 3. The spraynozzle system of claim 1, wherein the spray nozzle body includes aplurality of outlets and wherein each outlet of the plurality of outletsis (i) disposed on a rotatable turret and (ii) oriented to point in afirst direction.
 4. The spray nozzle system of claim 1, wherein theelectronic controller is configured to periodically release the fluidfrom a first outlet while continuously releasing the fluid from a secondoutlet.
 5. The spray nozzle system of claim 1, further comprising asensor (i) communicatively coupled to the electronic controller and (ii)configured to measure a speed of travel of the spray nozzle body,wherein the electronic controller is configured to generate the firstPWM signal and the second PWM signal based on the measured speed oftravel.
 6. The spray nozzle system of claim 1, further comprising asensor (i) communicatively coupled to the electronic controller and (ii)configured to measure a flow rate of the fluid out of the spray nozzlebody, wherein the electronic controller is configured to generate thefirst PWM signal and the second PWM signal based on the measured flowrate.
 7. The spray nozzle system of claim 1, further comprising a sensor(i) communicatively coupled to the electronic controller and (ii)configured to measure a pressure of the fluid into the spray nozzlebody, wherein the electronic controller is configured to generate thefirst PWM signal and the second PWM signal based on the measuredpressure.
 8. A spray system for a fluid, comprising: a plurality ofnozzle bodies configured to mount on a boom, wherein: each nozzle bodyof the plurality of nozzle bodies includes a fluid inlet, a first valve,a second valve, a first outlet, and a second outlet, the first outletand the second outlet join together to form a combined outlet, the fluidinlet is coupled to the first outlet via a first valve, the fluid inletis coupled to the second outlet via a second valve, and the fluid is (i)received at the fluid inlet, (ii) separated into two flow paths, and(iii) recombined into a single flow path at the combined outlet; and acontroller (i) in electrical communication with the first valve and thesecond valve of each nozzle body of the plurality of nozzle bodies and(ii) configured to move the first valve and the second valve of at leastone nozzle body of the plurality nozzle bodies according to at least oneof a first control mode, a second control mode, or a third control mode,wherein: in the first control mode, the fluid is released from both thefirst outlet of the at least one nozzle body based on a firstpulse-width-modulated (PWM) signal and the second outlet of the at leastone nozzle body based on a second PWM signal, in the second controlmode, the fluid is released from only one of the first outlet of the atleast one nozzle body based on the first PWM signal or the second outletof the at least one nozzle body based on the second PWM signal, and inthe third control mode: the fluid is released from the combined outletof the at least one nozzle body based on the first pulse-width-modulated(PWM) signal and the second PWM signal, the first PWM signal is of afirst time-duration and the second PWM signal is of a secondtime-duration, the first PWM signal is in a predetermined phase relationrelative to the second PWM signal such that fluid is released at agreater frequency from the combined outlet than from either the firstvalve or the second value of the at least one nozzle body, separately.9. The spray nozzle system of claim 8, wherein in the third controlmode, the first PWM signal has a first frequency, the second PWM signalhas a second frequency, and the first frequency is equal to the secondfrequency.
 10. The spray system of claim 9, wherein in a first sub-modeof the third control mode, the predetermined phase relationship is anin-phase relationship and in a second sub-mode of the third controlmode, the predetermined phase relationship is an out-of-phaserelationship.
 11. The spray system of claim 8, wherein the controller isconfigured to move the first valve and the second valve of the at leastone nozzle body according to at least two of the first control mode, thesecond control mode, and the third control mode.
 12. A spray systemcomprising: an agricultural vehicle having a boom; and a plurality ofnozzle bodies mounted along a length of the boom, wherein each nozzlebody of the plurality of nozzle bodies includes: a fluid inlet, a firstvalve, a second valve, and a combined outlet, wherein (i) the fluidinlet is coupled to the combined outlet via the first valve and thesecond valve, (ii) fluid received at the fluid inlet is separated intoat least two flow streams via the first valve and the second valvebefore recombining into a single flow stream at the combined outlet, and(iii) the fluid inlet is coupled to a first outlet via a first value anda second outlet via a second valve, and a circuit: in electricalcommunication with (i) an electronic controller, (ii) a first actuatorassociated with the first valve, and (iii) a second actuator associatedwith the second valve, and configured to generate, in response toreceiving a control signal from the electronic controller, (i) a firstpulse-width-modulated (PWM) signal for the first actuator, and (ii) asecond PWM signal for the second actuator, wherein: the first PWM signalis of a first time-duration and the second PWM signal is of a secondtime-duration, the first PWM signal has a first frequency, the secondPWM signal has a second frequency, and the first PWM signal is in apredetermined phase relationship relative to the second PWM signal suchthat fluid is released at a greater frequency from the combined outletthan from either the first valve or the second value of at least onenozzle body of the plurality of nozzle bodies.
 13. The spray system ofclaim 12, wherein the first frequency is equal to the second frequency.14. The spray system of claim 13, wherein in a first mode, thepredetermined phase relationship is an in-phase relationship and in asecond mode, the predetermined phase relationship is an out-of-phaserelationship.
 15. The spray system of claim 12, wherein each nozzle bodyof the plurality of nozzle bodies includes a rotatable turret and thecombined outlet is disposed on the rotatable turret.
 16. The spraysystem of claim 12, further comprising: the electronic controller; and asensor (i) communicatively coupled to the electronic controller and (ii)configured to measure a speed of travel of at least one nozzle body ofthe plurality of nozzle bodies, wherein the electronic controller isconfigured to generate the control signal based on the measured speed oftravel.
 17. The spray system of claim 12, further comprising: theelectronic controller; and a sensor (i) communicatively coupled to theelectronic controller and (ii) configured to measure a flow rate of thefluid out of at least one nozzle body of the plurality of nozzle bodies,wherein the electronic controller is configured to generate the controlsignal based on the measured flow rate.
 18. The spray system of claim12, further comprising: the electronic controller; and a sensor (i)communicatively coupled to the electronic controller and (ii) configuredto measure a pressure of the fluid into at least one nozzle body of theplurality of nozzle bodies, wherein the electronic controller isconfigured to generate the control signal based on the measuredpressure.